Products, methods and apparatus for fresh meat processing and packaging

ABSTRACT

Improved processing and packaging for perishable goods such as red meats providing a processing system wherein ambient air is excluded and suitable gases such as carbon dioxide are provided at a suitable pressure and in such a manner as to increase the quantity of the gases dissolved in the perishable goods. Then providing a base and placing the perishable goods over the base. A flexible web of plastic wrapping material (second web) is then applied over the base and the goods and air or gas evacuated therefrom and replaced with a suitable gas. The base includes a cup-shaped tray with a recess (first web), of plastics or other suitable material, with side walls extending upwardly to connect to a narrow horizontally disposed flange. The first web, goods and second web are located inside a depression in a third web of gas barrier material and there together placed into an enclosed evacuation chamber. A suitable gas is provided in the chamber in such a manner as to displace substantially all other gas and particularly atmospheric oxygen that may be present with the enclosed goods and web materials. The third web is then sealed so as to enclose the goods with first and second webs. that the pressure of the gas may be increased to a level above atmospheric pressure. Most preferably the quantity of gas dissolved into the goods will be increased. Most preferably the gas introduced into the chamber and the space will enhance preservation of the packaging goods when contacting the goods. The first web, second web and third web are sealed together thereby producing a hermetically sealed package with the goods and a gas filled space contained therein to provide a sealed package. The sealed package can be stored for any convenient period of time after which the third web is can be removed so as to allow ambient air to contact the goods. The invention further includes the method and apparatus for producing the processed goods and packaging.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation-in-part of prior application Ser. No.09/550,399, filed Apr. 14, 2000, which in turn is a continuation-in-partof application Ser. No. 09/392,074, filed Sep. 8, 1999, which in turn isa continuation of application Ser. No. 09/039,150, filed Mar. 13, 1998,now abandoned, which in turn claims the benefit of U.S. ProvisionalApplication No. 60/040,556, filed Mar. 13, 1997. In addition, thisApplication claims the benefit of U.S. Provisional Application Ser. Nos.60/129,595, filed Apr. 15, 1999; 60/141,569, filed Jun. 29, 1999;60/144,400, filed Jul. 16, 1999; 60/148,227 filed Jul. 27, 1999;60/149,938, filed Aug. 19, 1999; 60/152, 677, filed Sep. 7, 1999;60/154,068, filed Sep. 14, 1999; 60/160,445, filed Oct. 19, 1999; and60/175,372, filed Jan. 10, 2000.

FIELD OF THE INVENTION

The present invention relates to products, methods, apparatus, and theproducts made therefrom used for processing and packaging perishablefoods and particularly to processed perishable foods that are packagedin plastic food trays that are overlaid with one or more layers ofsealable plastic materials. The present invention also relates toapparatus for processing and pre-treating perishable foods andassociated packaging with gases.

BACKGROUND OF THE INVENTION

For the entire history of fresh red meat processing for humanconsumption, where slaughtered, eviscerated, and chilled carcasses areproduced in the normal process, improvements in terms of reducing laborand or reducing costs of the process, have been sought. Few majorimprovements have been achieved in the recent past and it is a purposeof this present invention to expose opportunities and to providemethods, apparatus and products of improving the efficiency andcompetitiveness of the red meat industry. Such opportunities areepitomized by, for example, the condition that all carcasses contain agreat deal of bone and other materials that are not used for humanconsumption and yet the entire carcass must be chilled prior to furtherprocessing, in order to chill those parts that are used for humanconsumption. Furthermore, the shape of all animals used for humanconsumption are of irregular and inconvenient profile. Conversely,packaging trays that have been cost effectively and efficientlymanufactured, are invariably rectangular and/or square in profile. Byadopting procedures disclosed herein it will be seen that costs ofchilling are reduced since, for example, the skeleton can be removedbefore chilling thereby saving costs of such chilling process. Fresh redmeat tissue is typically quite soft and easy to cut immediately afterthe animal has been slaughtered and prior to the natural, “hardening”effects of rigor mortis has occurred. It can therefore be easier andquicker to cut primal portions from animal carcasses, during the normalanimal “disassembly” process prior to rigor mortis and chilling. Thosefresh red meat primal items, that are intended for human consumption,can then be shaped by placing into molds of a specifically designed anddesired profile prior to rigor mortis and then chilled during thenatural rigor mortis process. This device will provide a method tochange and adjust the shape of fresh red meat primal items so that, forexample, fresh red meat primal items can be readily and automaticallyprocessed during the slicing and cutting process as required prior topackaging. Furthermore, profiles of primal meat portions can be arrangedso as to be more convenient when slices of fresh red meat primal itemsare loaded into improved packaging, such that more can be loaded intoimproved packaging while still maintaining a space efficient, appealingand attractive appearance for the consumer at the point of retaildisplay and/or foodservice outlet.

Typical modified atmosphere packages for fresh foods, such as red meatsand other perishable foods, having a limited shelf life, typicallyinclude a thermoformed tray or other package composed of EPS/tie/PE(barrier foam trays) plastics material or other suitable substantiallygas impermeable material, i.e. tray, overlaid with a single transparentweb of plastics material that can be heat sealed to the tray. A typicalsubstantially gas impermeable heat sealable composite web includes abiaxially oriented polyester (PET) layer/tie layer/gas barrier layer(such as PVDC) an adhesive layer/heat sealing layer (such aspolyethylene), which in turn is finally adhered by a heat sealer to thetray. The polyethylene layer is a heat sealable layer that is tied to agas barrier layer such as polyvinylidene chloride which is in turnadhered to polyester. Because of the diverse types of materials that areemployed in the foregoing package, it is difficult to reprocess andrecycle the post-consumer package. Moreover, the cost associated withpost-consumer recycling of multiple layer plastics material renders theprocess impractical and substantially not economically feasible.

Commonly used modified atmosphere packages for fresh foods such as redmeats and other perishable foods having a limited shelf life typicallycomprise a tray thermoformed from a sheet of EPS (expanded polystyrene)laminated to a web of substantially gas impermeable web material orother suitable substantially gas impermeable material. A lid, such as asingle or composite transparent web of plastics material that can bebonded to the flanges of the tray. Both tray and lid materials aretypically substantially gas impermeable heat sealable compositestructures and cannot be readily recycled. Lid material typicallycomprises a laminated structure including several layers such asbi-axially oriented polyester bonded to a gas barrier layer (such asPVDC) which is sandwiched between an adhesive or heat sealing layer(such as polyethylene). Because of the diverse types of materials thatare employed in the foregoing package, it is difficult to reprocess andrecycle the “post-consumer” package. Moreover, the cost associated withpost-consumer recycling of multiple layer plastics material, such as theaforementioned, renders the process impractical and substantially noteconomically feasible.

A further limitation of packaging perishable goods such as fresh redmeats in hermetically sealed gas barrier packages results from the needto enclose a relatively large volume of gas, and particularly carbondioxide, within the package. Clearly, consumers have no interest inpurchasing these gases that accompany the red meat. Minimizing the sizeand bulky appearance of such packaging is desirable, therefore it is agoal to reduce the overall size and volume of the packaging to a minimumsize. Additionally, a major proportion of red meat production occurs atlocations that are located at a substantial distance from the point ofretail sale of red meats to consumers. Most US beef is produced in thecentral plains around Kansas, Nebraska and Iowa and the major marketsare situated on the coastal regions such as New York or California.Costs of shipping these fresh red meat items from the point ofproduction and packaging can be reduced if the packages are reduced involume. However, reduction in the volume of gases provided within apackage can have a deleterious effect on shelf life of the perishablegoods and red meat contained therein.

Typical methods used for production of ground meats and patties, thatare substantially composed of fat, muscle tissue, protein and water,have remained unchanged for many decades and are inefficient whencompared with other food production methods that are commonly applied inother industries. These inefficiencies that result in large part frompoor controls and questionable safety standards, often cause significantand unnecessary wastage of meat in addition to occasional loss of humanlife.

A limitation of producing perishable goods such as fresh beef patties atthe point of source animal slaughter results from shelf life limitationsinherent with current packaging systems. A major proportion of beefpatties production occurs at locations that are situated at asubstantial distance from the point of sale of these products. Beefpatties are often produced at locations remote from the point ofslaughter due to short shelf life. The present invention provides animproved, automated fresh pattie processing system that can be readilyintegrated at the point of animal slaughter.

The packaging industry has therefore felt the need for simplifiedindividual packaging structures that will provide finished packageperformance including label requirements for a variety of applications.Additionally, if the packaging can be handled economically both in thepre-consumer handling and in post-consumer recycling, significanteconomic advantages are available.

With conventional packaging of meats and other perishable type goods,the shelf life is limited due to bacterial growth within the package.The growth can be inhibited when the package contains carbon dioxidegas, however, carbon dioxide will dissolve in liquids such as watercontained within the goods in the package. After time, carbon dioxidecan become substantially dissolved in the water and shelf life may belimited by this. After time, discoloration due to formation of, forexample, metmyoglobin on the outer surface of the red meat also reducesconsumer appeal of the packaged goods. It is also known to provide othergases within the package to enhance the keeping of the packaged goods.In the case of red meat blends of CO₂ and N₂, in varying proportions andup to 100% of each single gas have been used. When carbon dioxidedissolves into liquids and water, this can cause the package to collapseinwardly. Collapsing causes the appearance of the package to beunacceptable to consumers and can also cause the package to rupture.

In order to extend shelf and storage life of the packaged goods severalinventions have been disclosed and examples of known packaging for thispurpose are given in the following US patents: 5,779,832 Kocher Methodand Apparatus for making a peelable film 5,629,060 Garwood Packagingwith Peelable Lid 5,560,182 Garwood Packaging Method 5,534,282 GarwoodPacking Perishable Goods 5,514,392 Garwood Packaging for PerishableGoods 5,323,590 Garwood Method of producing food packaging with gasbetween tensioned film and lid 5,226,531 Garwood Food Packaging with gasbetween tensioned film and Lid 5,155,974 Garwood Food Packaging with gasbetween tensioned film and Lid 5,115,624 Garwood Thermoplastic skinpacking means 5,129,512 Garwood Packaging

The subject matter of the above patents is hereby incorporated byreference.

Prior art as described in U.S. Pat. No. 5,779,832 to Kocher, discloses amethod of making a multilayer peelable film. Kocher discloses a methodof co-extruding two webs of material simultaneously in the form of amultilayer film that can be delaminated into a third web and a secondweb and then after treating the second web to improve gas permeabilitytherethrough, re-laminating the third and second webs together. Thesetwo re-laminated webs can be sealed to a first web of gas barriermaterial and thereby produce a package. The first web may have adepression formed therein into which goods such as red meat can beplaced before heat sealing the third and second webs to the first web.Typically, goods will not completely fill the depression and space willremain in the depression in addition to the goods. A blend of gases or asingle gas such as CO₂ can be provided in the space with the goods andthereby can contact the goods. After storage and prior to retail displayat an intended point of sale to consumers, the third web can be peeledfrom the package allowing atmospheric oxygen to permeate the second webof gas permeable material and to contact the goods. The atmosphericoxygen can then allow generation of a bright red colored substance suchas oxymyoglobin thereby providing an appearance attractive to theconsumers.

It has been found that when applying the second and third webs extrudedin the manner as disclosed in Kocher to packaging as that disclosed inthe inventor's own U.S. Pat. No. 5,534,282, a dull appearance of thesecond web can result with reduced clarity when compared with other websof material that are produced in a single web such as plasticized PVC(pPVC). Furthermore, after removal of the third web, from there-laminated co-extrusion, by peeling, as described in U.S. Pat. No.5,534,282, distortions and ripples can appear in the second web. Thisoccurs, partly, as a result of inadequate lateral tension provided inthe second web when limited by the inherent limitations of co-extrudingthe second and third webs simultaneously. This can, therefore, severelydetract from the visual appearance of the package in the eyes ofconsumers.

A further limitation of packaging perishable goods such as fresh redmeats in hermetically sealed gas barrier packages results from the needto enclose a relatively large volume of gases, and particularly carbondioxide, within the package. Clearly, consumers have no interest inpurchasing gases with red meat and minimizing the size and bulkyappearance of the package is desirable. Additionally, a major proportionof red meat production occurs at locations that are situated at asubstantial distance from the point of sale for red meats. Costs ofshipping the goods from point of production and packaging can be reducedif the packages are reduced in size. However, reduction in the volume ofgasses contained within a package can have a deleterious effect on theshelf life of perishable goods and red meats contained therein.

Conventional modified atmosphere “case ready” retail packaged fresh redmeats and other perishable type goods experience limited shelf lifebecause of bacterial growth, such as aerobic and anaerobic bacteria, onthe packaged goods; rancidity “off flavors” caused, in part, byoxidizing fats; and discoloration to visible meat surfaces. The growthcan be inhibited when goods are treated by exposure to certain agentsprior to packaging and then providing certain gasses and/or other agentswith the goods within the finished and sealed package. Such a gas, blendof gasses agent or agents may include one or a combination of thefollowing: oxygen, carbon dioxide, ozone, hydrogen, nitrogen, argon,krypton, neon, helium, xenon, hydrogen peroxide, potassium permanganate,chlorine dioxide, fluorine, bromine, iodine and/or any other suitablesubstances. However, some gasses such as carbon dioxide gas, forexample, can quickly dissolve in substances such as oils and watercontained in the goods. After time, carbon dioxide can becomesubstantially dissolved in water which may limit shelf life.Furthermore, when oxygen is present and more particularly when aquantity of approximately 5,000 to 30,000 parts per million of oxygen ispresent in a gas within a package, discoloration due to formation ofmetmyoglobin on the visible surface of red meat, reduces consumer appealof the packaged goods. When carbon dioxide dissolves (into anothersubstance) the combined volume of the residual substances issubstantially reduced which can cause the package to collapse inwardly.Collapsing causes the appearance of the package to be unacceptable toconsumers and can also cause the package to rupture and render it unfitfor use. In compensating for such a deleterious event, several existingpackaging systems require large volumes of gas to be packaged with thegoods. However, when large volumes of gas are provided, the resultant“bulky” condition does not provide for cost efficient shipping anddistribution from the location of packaging to the point of retail saleof the packaged goods.

Conventional packages for red meat are produced in one or more sizes.When packaging red meats or other perishable goods, the package mustconform to the goods. Therefore, if a red meat portion is too large forone size of a package, the next larger size must be used. Oftentimes,this will lead to an overly large sized package introducing inefficiencyinto the process because of the wasted space. In order to maximizeefficient use of the internal space available in a typical road, rail orsea, refrigerated shipping container or trailer, it is important toincrease the density and unit weight per unit volume of the packagedperishable goods. The maximized efficient use of the space in theshipping containers can be achieved by adjusting the shape of theinconveniently shaped animal fresh red meat primal portions such thatslices of the fresh red meat primal portions will fit and substantiallyfill the available space within trays of the improved packaging.

High oxygen case ready packages are inefficient, in large part, due tothe inherent need to include a quantity/volume of gas that is equal to,or greater than the volume of the package meat contents. For example, ahigh oxygen package comprising a barrier foam tray and clear barrierfilm lid, hermetically sealed to flanges of the barrier foam tray andwith a 2 lb quantity of meat sealed therein will require approximately 1liter of gas to be enclosed and sealed within the package to ensure thatan approximate 10 day shelf life extension can be provided. Said gas(referred to as modified atmosphere) will typically comprise 80% Oxygenand 20% Carbon Dioxide but other combinations that may includerelatively small quantities (say <10%) of residual atmospheric nitrogenare also typical. The relatively high level of CO2 (when compared toambient atmosphere) is provided to inhibit bacterial growth, and withgood storage temperature control a shelf life for sound, fresh meat canbe extended to over 10 days from packaging. The bacterial controllingeffect is a consequence, in part, of a characteristic of bacteriaentering a “lag phase” when the environment in which it is placed,significantly changes . . . eventually the bacteria will equilibrate andadapt to the atmosphere that is present and commence normal reproductionand extended infection. The shelf life extension will vary according toseveral factors including, for example, the following: storagetemperature ie: the less variation from a minimum temperature ofapproximately 29.5 degrees F. is optimum, (while ensuring that freezingof the meat, which occurs at about 26-27 degrees F., does not occur);the condition and age of the meat at packaging, the conditions at thepoint of packaging such as hygiene, temperature etc., muscle type andage of animal from which the meat was harvested. Nevertheless, a shelflife extension of 10 days is readily reproducible when conditions aremaintained as required. After a relatively short period of time, the CO2provided within the package will dissolve into the water and oilscontained in the meat and the oxygen is present to ensure that aconsumer appealing/acceptable “bloom: or “redness” is maintained. The“bloom” is caused by the natural color of oxymyoglobin and oxyhemoglobinthat is present in freshly cut meat but when oxygen is present, afterapproximately 9 to 10 days discoloration such as browning due toincreased levels of surface metmyoglobin, will occur, rendering theproduct unsaleable or requiring a reduction in price to sell to aconsumer. Furthermore, the excessive volume of the finished packages,results in excessive packaging material and shipping costs and displaycase space at retail outlets and also excessive costs incurred fordisposal of additional cardboard etc. at the supermarket outlets.Therefore by reducing volume of the retail package, costs for packaging,shipping and display are substantially reduced, which is a purpose ofthe inventions.

Effective packaging materials for existing, extended shelf life, retailpackaged, case ready perishable goods are often relatively expensive andthe associated packaging processes are typically labor intensive. Theuse of EPS and FP can provide desirable low cost packaging materials butthe inherent cell structure of these materials can retain residualoxygen (from air) within the cell structure, even during and afterexposure to very low levels of air pressure (vacuum). When EPS and FPmaterials are used in low residual oxygen modified atmosphere packaging,such as described in U.S. patent application Ser. No. 09/039,150,residual oxygen can diffuse and exchange from the cell structure, andbecome present as a free gas within the master container therebyelevating the level of oxygen present therein to a potentiallyundesirable level. As described in the subject matter of US patentapplications in the name of the present inventor, apparatus forminimizing the level of residual oxygen retained in the cell structureand master containers are disclosed. However, such a process of gasexchange is problematic and difficult to reliably maintain. Therefore,packaging fabricated from solid plastics sheet, may be more efficientlyemployed in this application.

Conventional “master container” or “master package” modified atmospherepackaging (MAP) systems include loading perishable goods into trays andthen a plurality of loaded trays are subsequently placed into a larger“master container” which may be manufactured from a suitable gas barriermaterial. The “master container” is typically evacuated of air and thenfilled with a gas blend that may include a mixture of any desirablegasses which may include, for example, 40% carbon dioxide and 60%nitrogen for a low oxygen MAP system. The master container is thensealed with loaded trays to provide an airtight, sealed mastercontainer, containing loaded trays and a gas blend with a residualquantity of atmospheric oxygen. Most desirably, for low oxygen MAPsystems, the residual quantity of atmospheric oxygen will not exceed anamount of 100 to 300 PPM (parts per million) with the balance of the gasblend including nitrogen and carbon dioxide and/or other inert or oxygenfree gasses. Low cost packaging materials include foamed polystyrene(EPS trays), however, the choice of material for tray manufacture mustexclude materials (unless treated in a manner that will substantiallyremove atmospheric oxygen from the cell structure), such as expanded(foamed) polystyrene (EPS), that have a capacity to “retain” air, evenafter exposure to a high vacuum as may occur in packaging processes.Therefore, in order to maintain the residual quantity of atmosphericoxygen at not more than 100 PPM, untreated expanded (foamed) polystyrene(EPS) or FP trays cannot be easily and efficiently used. By way ofexplanation, EPS trays are typically thermoformed from extruded EPSsheet. A typical method of producing EPS sheet is to “foam” the melted(liquid) polystyrene by injection of a foaming agent, such as nitrogen,carbon dioxide or pentane, into liquid polystyrene thereby causing it tofoam (become frothy, with bubbles and/or tiny gas filled cells withinthe foam) and then extrude the foam through a slot in a flat or annulardie. The extruded EPS can then cool and solidify into a sheet that canbe slit and wound onto a roll prior to further processing. Immediatelyafter extrusion of the EPS sheet, cells retained within the foam arefilled with nitrogen or other gas (foaming agent) used in the foamingprocess. However, such a foaming agent gas, if not retained by othermeans in the cell structure, can quickly exchange with the ambient airduring storage and the cells can become filled with air. When placedwithin a vacuum chamber and exposed to a high level of vacuum, as isnormal in a “master container” packaging process for low oxygen MAPsystems, cells can retain a quantity of air, even during and subsequentto evacuation (unless the exposure to vacuum is significantly extendedto the extent required). The retained quantity of air in the cells, cansubsequently exchange with gas within the sealed “master container”which can, thereby, elevate the residual oxygen content of the “free”gas contained within the “master container” above a desirable level.

A fundamental need that resulted in the development of thermoformed EPStrays initially arose in the modern supermarket. Fresh meats and poultrywere formerly processed and retail packaged at the supermarketimmediately prior to retail display and sale. EPS foam trays weredeveloped to meet these supermarket requirements, and have provided afunctional and low cost retail package, when “over wrapped” with a lowcost web of plastic material such as plasticized PVC. However, with caseready MAP systems, such EPS trays are now required to be shipped intrucks and other means of transport from the point of packaging, whichmay be located many hundreds of miles from the point of sale. Abuse anddamage can occur to the packaging during this shipping. In an effort toprotect against damage, rigid and heavy weight cartons with sheets,cushions and/or columns, made from suitable materials such as chipboardare manufactured and assembled with EPS trays and goods containedtherein. Such protective packaging is expensive, bulky and results inexcessive shipping costs. Furthermore, excessive packaging, as requiredfor the sole purpose of protection during shipping, must be discarded atthe supermarket thereby creating excessive waste disposal problems withthe attendant costs to the environment.

SUMMARY OF THE INVENTION

Methods and apparatus of the present invention are directed atsaturating fresh meat with CO₂ prior to packaging. In this situation,adequate CO₂ can be dissolved in the tissue of the meat and to such alevel that the meat can become a source of CO₂ after packaging. This canbe achieved by lowering the temperature of the meat to a minimum(typically about 29.5 degrees F.) and exposing it to relatively highpressure (ambient to 200 psi or more) CO₂ gas. CO₂ gas dissolves morereadily at lower temperatures and therefore a part of the method is toexpose the meat to high pressure CO₂ at the lowest temperature abovefreezing and then retail package the meat in a tray, then over wrappedwith a highly gas permeable web of material such as pPVC. If an extendedshelf life of say not more than 10 days is adequate, then a barrierpouch master container may not be needed, the CO₂ gas “entrained” in themeat tissue prior to packaging will gradually be released immediatelyafter removal from a higher pressure to ambient and as the temperatureelevates during delivery to the point of sale and this can be sufficientto inhibit bacterial growth and atmospheric oxygen in unlimitedquantities is available to maintain the requisite “bloom”. In this way,shipping, packaging and display costs can be reduced substantially,while providing an extended shelf life which may be sufficient for someindustry packers and supermarkets.

Thus, the present invention discloses a method of processing andpackaging goods, the method having a step for placing goods in anenclosed vessel containing a gas to enhance the keeping of the goods, astep allowing the gas to contact and dissolve in liquids and oilspresent in the goods, a step restricting the formation of oxymyoglobinby substantially displacing ambient air, that may otherwise contact thesurface of the goods, with the gas, a step providing a retail packageincluding two overlapping webs with a space therebetween with at leastone of the webs being gas permeable, a step transferring the meats fromthe vessel to a position between the two overlapping webs and into thespace without allowing significant formation of oxymyoglobin on surfaceof the meats.

In a preferred embodiment, the method is suitable to use on goodsincluding fresh red meats wherein the gas is a substantially oxygen freegas.

A further embodiment is a method of packaging goods, the method having astep providing four or more overlapping web sections, the two outer,first and second, web sections being gas barrier webs, the inner websections having folded, third web material with at least one cup-shapeddepression therein that restricts nesting of the webs together, and afourth gas permeable web material with space between the third andfourth web sections, a step providing goods between the folded third webmaterial and the fourth web material, a step for sealing the foldedthird web material and the fourth web material so as to substantiallyretain the goods in the cup-shaped depression but allowing gas to passinto and out of the space, a step for sealing the overlapping webs aftersealing the third and fourth web material but prior to sealing the firstand second webs together at a seal path near the perimeter of thepackaging which will provide a hermetically sealed package, a step forgas flushing the chamber means with a gas to enhance the keeping of thegoods, a step for sealing the first and second webs together by asealing means which defines a seal path near what will be an outerperimeter of the packaging and which encloses the third and fourth webmaterial within a hermetically and substantially gas impermeable packagewith the goods and the gas sealed therein and allowing the gas tocontact the goods.

A further embodiment includes one or more packaging tray(s), eachfabricated from a single web of thermoformed plastics material web. Saidpackaging tray having upwardly disposed side walls, definingdepression(s) with space therein into which goods are placed, a secondweb of gas permeable material overlapping said first web which may havebeen stretched over said packaging tray with goods therein andhermetically sealed to fully enclose said packaging tray and goodstherein, a third web of gas impermeable material overlapping andhermetically sealed so as to fully enclose one or more of said first andsecond webs with space therein, a suitable gas in said space, said gasor blend of gases selected for enhancing preservation of the packaginggoods by contacting the surface of said goods, a chamber means toenclose said first, second and third webs, prior to sealing said thirdweb, which can be isolated from external atmosphere by valve means,providing a suitable pressure to said gas in said chamber, hermeticallysealing said third web.

A further embodiment is a goods packaging tray having a base withupwardly extending side walls that terminate at a flange that extendsaround a perimeter of the tray to provide a cup-shaped recess. The trayhaving at least one extension connected to the flange at a hinge. Theextension having a cup-shaped flap that can be folded about the hingeand be sealed to at least one of the upwardly extending side walls toprovide an enclosed space. The tray having apertures at a base of theside wall of the tray so as to provide communication between theenclosed space and the tray that will allow liquids to pass from thetray cup-shaped recess to the enclosed space.

A further embodiment is an apparatus for producing packaging trayshaving means for thermoforming plastics sheet to form and trim apackaging tray with a base and upwardly extending side walls thatterminate at a flange that extends around a perimeter of the tray toprovide a cup-shaped recess with at least one extension connected to theflange at a hinge having a cup-shaped flap that can be folded about thehinge and be sealed to at least one of the upwardly extending side wallsto provide an enclosed space. The apparatus further includes a sealer toseal the flap to the tray wall around a perimeter of the flap and adevice to optionally provide apertures in the side wall of the trayrecess so as to provide a communication between the enclosed space andthe tray recess.

A further embodiment includes a method and apparatus for grindingboneless beef directly into an enclosed chamber that has been filledwith a suitable gas such as CO₂ and which substantially excludes oxygenfrom contacting with the ground beef. Adjusting temperature of theground beef to a suitable temperature.

Processing and mixing ground beef (meat), in a vessel or series ofvessels substantially excluding oxygen, so as to blend and adjust therelative quantities of fat and muscle in the finished product to adesired ratio. Maintaining the ground beef at a suitable temperature.

Extruding ground beef in a stream of grinds by pumping through anenclosed conduit with an exit end and a selected cross sectional areaand profile that is substantially similar to typical beef patty, at avelocity that is adjustable while maintaining pumping at a substantiallyconstant rate. Pressurizing a stream of ground beef in a conduit at aselected pressure and compressing any voids such that CO₂ gas containedtherein dissolves into the stream of ground beef. Maintaining groundbeef at a suitable temperature.

Intermittently adjusting the velocity of stream of grinds so as tointermittently slow or stop its flow as it emerges from the exit end ofthe enclosing conduit and allow slicing with knife means to providesingle beef patties in stacks of a chosen quantity. Intermittent slowingor stopping of flow may exceed 500 cycles per minute.

Interfacing with a packaging system and packaging fresh meat pattieswithout exposure to air while maintained at a suitable temperature.

The present invention provides an efficient method and apparatus forprocessing fresh red meat products at the point of animal slaughter forsubsequent case ready packaging and delivery to the consumer via atypical supermarket or retail sale outlet. The consumer may be locatedthousands of miles away from the point of slaughter which often resultsin distribution and delivery that can require a period of time exceeding20 days.

The present invention provides a most efficient method and apparatus forpackaging fresh red meat products at the point of animal slaughter forsubsequent delivery to the consumer via a typical supermarket or retailsale outlet. Consumers, located thousands of miles away from the pointof slaughter and packaging often results in distribution and deliverythat can require a period of time exceeding 15 days.

The present invention maximizes efficient use of the internal spaceavailable in a typical road, rail or sea, refrigerated shippingcontainer or trailer, it is important to increase the density and unitweight per unit volume of said packaged perishable goods. Effectivepackaging materials for existing case ready packaging systems are oftenexpensive and the associated packaging processes are typically laborintensive. The present invention provides low cost packaging trays byutilizing various packaging materials such as polypropylene or PET.

The present invention provides improved packaging for perishable goods,an improved appearance of the packaging and a means to increase thelevel of carbon dioxide dissolved into the liquid and water contained onor with the perishable goods, thereby reducing the total volume of thepackages, increasing density for more efficient shipping and subsequentdisplay at the point of sale. The goods includes fresh red meat and afurther purpose of this invention is to provide a means of enhancing thekeeping qualities of the goods.

The present invention provides several alternative methods of stretchingthe second web such that after removal of the third web, the second webwill be in a substantially “ripple free”, clear, smooth, and at leastpartially tensioned condition. Additionally, a further description of amethod to pre-stretch the second web, before sealing the first web,second web and third webs, within a single chamber sealing means isdisclosed. A further description of methods to package goods in a singlechamber sealing and packaging machine when the first and second webs areapplied separately without having been re-laminated after treatment ofthe second permeable web.

Therefore in accordance with a first broad aspect of the presentinvention there may be provided improved packaging for perishable goodsincluding: a tray or first web over which the goods are placed, thegoods including oils, fats, protein, liquids and water. The tray havingupwardly disposed side walls, defining a depression with space therein,the side walls having been urged inwardly to a controlled andpredetermined extent and are tensioned, thereby retaining an outwardlyurging force; a second web of gas permeable material overlapping thefirst web which may have been pre-stretched; a third web of gasimpermeable material overlapping the first and second webs; a gas in thespace, the gas or blend of gasses (preferably carbon dioxide andnitrogen) selected for enhancing preservation of the packaging goods bycontacting the surface of the goods; a chamber means to enclose thefirst, second and third webs, prior to sealing, which can be isolatedfrom external atmosphere by valves, providing pressure to the gas in thechamber, the pressure being at a level above ambient atmosphericpressure, thereby providing accelerating dissolving of the gasses andcarbon dioxide into the liquids and water; and sealing the first, secondand third webs together while retaining the side walls of the first webtray in tension with the second and third webs.

In this way, the shelf life of the packaged goods can be extended andwhen the third web is removed, the tension between the side walls andthe second web can cause the second web to be stretched and besubstantially flattened with fewer ripples in its surface. Thus thepackaging will be pleasing to an intending purchaser.

The invention provides a labor efficient, low cost processing andpackaging system for perishable goods that can minimize the presence ofundesirable levels of both anaerobic and aerobic bacteria, fungi, virusand residual oxygen, for an extended period of storage time by enhancingthe keeping qualities of the perishable goods. The processing andpackaging system is disclosed herein, with further disclosures providingdetails of several package configurations produced from variouspackaging materials including polypropylene, amorphous polyester,expanded polystyrene (EPS) and foamed polyester (FP).

Additionally, the present invention provides efficient methods andapparatus for delivering fresh red meat products from the point ofanimal slaughter and retail packaging to the consumer via a typicalsupermarket or retail sale outlet. The consumer may be located thousandsof miles away from the point of slaughter which often results indistribution and delivery that can require a period of time exceeding 14to 25 days.

The present invention provides methods and apparatus for reducing theprocessing costs, provide a method to reduce the labor content of theprocess and separate the carcass into at least two groups of componentsthat can be either used for human consumption or not for humanconsumption prior to chilling the carcass.

The present invention provides improved and accurate “portion control.”For example, a New York Strip primal that includes a strip of musclewith a fat covering on one side, can be substantially shaped into auniform strip prior to slicing. Additionally, such primal items astenderloin that have a tapered profile can be combined and pressedtogether to form a single tenderloin of uniform cross-section and thensliced to produce uniform slices of equal size and weight. In yet afurther embodiment, the present invention provides for the cutting ofmeat containing deoxymyoglobin in an atmosphere that excludes oxygen andsubstantially inhibiting and preventing contact of the freshly cutsurface with oxygen in the ambient atmosphere.

The present invention provides a labor efficient, low cost processingand packaging system for perishable goods that can minimize the presenceof undesirable levels of bacteria, rancidity, discoloration and enhancethe keeping qualities of the perishable goods.

Trays and packaging apparatus are disclosed in the present inventionthat can incorporate either a low oxygen modified atmosphere oralternatively a high oxygen modified atmosphere. A high oxygen modifiedatmosphere may include a blend of gasses including 20% carbon dioxide,70% oxygen and 10% nitrogen. Part of this blend of gas may include someresidual ambient atmospheric gases.

The tray construction and packaging disclosed in this invention describeways to substantially eliminate excessive packaging by incorporatingmultifunctional features in a single tray. The multifunctional featuresinclude devices to allow stacking of a plurality of trays in a verticalstack, incorporation of an in-built protective cushion around theperimeter of the tray and a purge absorbing feature.

Additionally, the present invention provides a most efficient means ofdelivering fresh red meat products from the point of animal slaughterand retail packaging to the consumer via a typical supermarket or retailsale outlet. The consumer may be located many hundreds of miles awayfrom the point of slaughter which often results in distribution anddelivery time that can exceed 14 to 25 days.

The present invention increases the volume of carbon dioxide gas withina package without increasing the size and volume of the package. Thiscan be achieved by carbonation and increasing the quantity of dissolvedcarbon dioxide in the free liquids, oils and water contained in thepackage with red meat prior to hermetically sealing the package.

In order to maximize exploitation of the benefits of improved packagingas described herein for use with packaging of perishable goods such ascuts of fresh red meat, as detailed herein, a method and apparatus ofchanging and/or adjusting the shape and profile of the red meat primal,before slicing the primal, such that slices of the primal will have apermanently adjusted shape facilitating more efficient use of theimproved packaging, is highly desirable. The description containedherein provides a method and apparatus of achieving an adjustment and orshape of large fresh red meat primal portions and combinations ofsmaller pieces pressed together.

The present invention provides a product, method and apparatus forprocessing fresh meats such as ground beef, lamb and pork and mostparticularly for production of ground beef, safe bulk storage, sale inbulk form, further processing, and packaging according to customerspecifications that are provided immediately prior to packaging andwhere the product and packaging specifications are provided by customervia electronic transfer of information, directly, or substantiallydirectly to the ground beef storage and packaging equipment. Said groundbeef, in whichever form, including beef patties, being intended or humanconsumption and made in accordance with the present invention. Thepresent invention provides an automatic and enclosed fresh meatsgrinding and/or cutting, blending, processing, storage and packagingprocess including the electronic business method of specifying andpurchasing the finished meat products according to the purchasersspecifications which may be specified immediately prior to production ofthe specified products.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing aspects and many of the attendant advantages of thisinvention will become more readily appreciated as the same becomesbetter understood by reference to the following detailed description,when taken in conjunction with the accompanying drawings, wherein:

FIG. 1 is a perspective view of one package made in accordance with thepresent invention;

FIG. 2 is a perspective view of a corner section of the package of FIG.1 with the heat sealable layers up turned;

FIG. 3 is a cross-sectional view of the package of FIG. 1 taken alongsection line 3-3;

FIG. 4 is a schematic view of an assembly line for manufacturing apackage such as shown in FIG. 1;

FIG. 5 is a schematic view of a master bag method of packagingindividual packages for storage and transport in accordance with thepresent invention;

FIG. 6 is an alternate embodiment of a tray having a vent hole inaccordance with the present invention;

FIGS. 7, 8, and 9 show another embodiment of a stackable tray built inaccordance with the present invention;

FIGS. 10-15 show another embodiment of a stackable tray constructed inaccordance with the present invention;

FIG. 16 shows another embodiment of a master package and method forstoring and transporting individual packages containing edible materialsin accordance with the present invention;

FIGS. 17 and 18 show an alternate valve arrangement to that shown inFIGS. 14 and 15;

FIGS. 19-21 show another alternate valve arrangement;

FIGS. 22-26 show the incorporation of a material for indicating thepresence of E. coli bacteria into a tray, constructed in accordance withthe present invention;

FIGS. 27-30 show a production line and method in accordance with thepresent invention for producing a material for indicating the presenceof E. coli bacteria.

FIG. 31 shows a perspective view of a tray with flaps constructedaccording to the present invention;

FIG. 32 shows a perspective view of the tray of FIG. 31;

FIG. 33 shows a cross-sectional view of the tray of FIG. 32 taken alongline 33;

FIG. 34 shows a finished package constructed according to the presentinvention;

FIG. 35 shows a master container constructed according to the presentinvention;

FIG. 36 shows the master container of FIG. 35 with finished packagesenclosed therein and sealed with a lid and enclosed in a cardboard box;

FIG. 37 shows a cross-sectional view of a tray constructed according tothe present invention;

FIG. 38 shows a perspective view of a finished package constructedaccording to the present invention;

FIG. 39 shows a cross-sectional view of a tray portion including a flapin the up position;

FIG. 40 shows a bottom plan view of the flap of FIG. 39;

FIG. 41 shows a cross-sectional view of the flap of FIG. 39 in the downposition;

FIG. 42 shows a schematic view of a tray sealing apparatus constructedaccording to the present invention;

FIG. 43 shows a web material constructed according to the presentinvention;

FIG. 44 shows a web material constructed according to the presentinvention;

FIG. 45 shows a cross-sectional view of a finished package constructedaccording to the present invention;

FIG. 46 shows a cross-sectional view of a web material constructedaccording to the present invention;

FIG. 47 shows a perspective view of a finished package constructedaccording to the present invention;

FIG. 48 shows a tray portion including a flap in a down position,constructed according to the present invention;

FIG. 49 shows a cross-sectional view of a web material constructedaccording to the present invention;

FIG. 50 shows a perspective view of a tray with flaps constructedaccording to the present invention;

FIG. 51 shows a bottom perspective view of the tray of FIG. 50;

FIG. 52 shows a bottom plan view of the tray of FIG. 50;

FIG. 53 shows a side plan view of the tray of FIG. 50;

FIG. 54 shows a cross-sectional view of a tray constructed according tothe present invention;

FIG. 55 shows a perspective view of a tray constructed according to thepresent invention;

FIG. 56 shows a cross-sectional view of a tray portion of FIG. 55 takenalong line 56;

FIG. 57 shows a cross-sectional view of a tray portion of FIG. 55 takenalong line 57;

FIG. 58 shows a cross-sectional view of a tray portion of FIG. 55 takenalong line 58;

FIG. 59 shows a cross-sectional view of a web material constructedaccording to the present invention;

FIG. 60 shows a perspective view of a tray constructed according to thepresent invention;

FIG. 61 shows a cross-sectional view of a tray portion of FIG. 60 takenalong line 61;

FIG. 62 shows a perspective view of stacked trays constructed accordingto the present invention;

FIG. 63 shows a cross-sectional view of the stacked trays of FIG. 62;

FIG. 64 shows a perspective view of a finished package constructedaccording to the present invention;

FIG. 65 shows a perspective view of a tray with flaps constructedaccording to the present invention;

FIG. 66 shows a schematic view of a tray portion including a flapconstructed according to the present invention;

FIG. 67 shows a cross-sectional view of a tray portion of FIG. 65 takenalong line 67;

FIG. 68 shows a cross-sectional view of a tray portion of FIG. 65 takenalong line 68;

FIG. 69 shows a detailed view of FIG. 68;

FIG. 70 shows a cross-sectional view of a tray portion including a flapconstructed according to the present invention;

FIG. 71 shows a cross-sectional view of a web material constructedaccording to the present invention;

FIG. 72 shows a cross-sectional view of a detailed tray portion of FIG.70;

FIG. 73 shows a cross-sectional view of a finished package with apealable label constructed to the present invention;

FIG. 74 shows a perspective view of the package with label of FIG. 73;

FIG. 75 shows a cross-sectional view of a finished package with overwrap web material constructed according to the present invention;

FIG. 76 shows a perspective view of the finished package of FIG. 75;

FIG. 77 shows a cross-sectional view of the finished package of FIG. 76with the over wrap in its loose state;

FIG. 78 shows a cross-sectional view of the finished package of FIG. 76with the over wrap in a stretched state;

FIG. 79 shows a cross-sectional view of a master container containingfinished packages, the master container being enclosed within acardboard box, constructed according to the present invention;

FIG. 80 shows a portion of the master container of FIG. 79;

FIG. 81 shows a portion of the master container of FIG. 79;

FIG. 82 shows a perspective view of a tray with flaps constructedaccording to the present invention;

FIG. 83 shows a cross-sectional view of the tray of FIG. 82 taken alongline 83;

FIG. 84 shows a pair of tray pre-forms with ribs that are arranged toprovide enclosed pressure vessels after sealing;

FIG. 85 shows a side elevation of a packaging tray that has beenmanufactured from a pair of pre-forms shown in FIG. 84;

FIG. 86 shows a cross-sectional view of a tray portion of FIG. 85 takenalong line 86;

FIG. 87 shows a cross-sectional view of the tray portion of FIG. 86taken along line 87;

FIG. 88 shows a three dimensional view of a complete packaging traycomprising a base 303 with four upwardly extending side wallsterminating at a continuous flange 901 that follows a path at aperimeter of the packaging tray and surround a cavity 110;

FIG. 89 shows a cross sectional view through the packaging tray shown inFIG. 88;

FIG. 90 shows a plan view of a thermoformed pre-form that can befabricated by folding and bonding to form a packaging tray as shown inFIG. 88;

FIG. 91 shows a cross-sectional view of a tray portion of FIG. 89;

FIG. 92A shows a plan view of a thermoformed pre-form that can befabricated by folding and bonding flaps 10, 11, 13, 16, 14, and 15 toform a packaging tray with cavity 12 as shown in FIGS. 95 and 96;

FIG. 92B shows a cross sectional view of a tray flap of FIG. 92A.

FIG. 93 shows two thermoformed and fabricated packaging trays 20 and 21,that are nested and stacked together to provide a stack of trays;

FIG. 94 shows a cross section through an apparatus that is arranged toseal flaps (such as 10, 11, 13, 16, 14, and 15 shown in FIG. 92) to thewalls of a packaging tray (such as shown in FIG. 92) to produce trayssuch as 40 and 41 shown in FIG. 95;

FIG. 95 shows a side elevation of two packaging trays that are stackedafter flaps, such as 10, 11, 13, 16, 14, and 15 shown in FIG. 92 havebeen sealed to walls of the tray;

FIG. 96 shows an end view of two packaging trays that are stacked afterflaps, such as 10, 11, 13, 16, 14, and 15 shown in FIG. 92 have beensealed to the corresponding walls of the tray;

FIG. 97 shows a three dimensional view of a packaging tray 60 with ribs62, 63, 65 and 66 formed into the profile of flaps and walls of thepackaging tray;

FIG. 98 shows a cross-sectional view of tray 60 in FIG. 6 taken alongline 2;

FIG. 99 shows a perspective view of a tray according to the presentinvention;

FIG. 100 shows a cross-sectional view of a tray portion of FIG. 99 takenalong line 100;

FIG. 101 shows a cross-sectional view through a segment of a preferredpackaging tray embodiment;

FIG. 102 shows a cross-sectional view of a tray portion of FIG. 101taken along line 102;

FIG. 103 shows details of the components used to manufacture a compositetray;

FIG. 104 shows a plan view of a web material to construct a trayaccording to the present invention;

FIG. 105 shows a cross section through an apparatus with housing 12, anda tapering screw 15 mounted therein; a piston 16, with correspondingcylinder 25, is mounted to housing 12 and a restricting conduit 18 isattached to the exit end of housing 12, grinds 20 can be transferredinto said housing 12 and screw 15 may be used for pumping said grindsinto a profiled conduit thereby providing an extruded stream of grindsfor subsequent slicing and thereby production of patties;

FIG. 106 shows a cross section through an apparatus intended for use inslicing extruded streams of ground meats to produce patties, atemperature controlled conduit 45 is mounted adjacent to a revolvingblade 47, such that stacks of sliced patties 51 and 52 can be producedand transported to a packaging station via conveyor belting 50 that isdriven intermittently by drive roller 49 in direction shown by arrow 52;

FIG. 107 shows a cross-sectional view of an apparatus portion of FIG.105 taken along line 107;

FIG. 108 shows a side elevation of an apparatus assembled to producefine ground boneless beef 77, from coarse ground boneless beef 61, afterfine grinding into vessel 70 from grinder 65, ground beef 77 is pumped,in the direction shown by arrow 74, via servo driven positivedisplacement pump 71, through conduit 73 which can be connected directlyto conduit 9, shown in FIG. 1. Conduit connections 66 and 78 areprovided to allow injection of gas such as CO₂ there through and conduitconnection 79 is provided to allow gases to be withdrawn from vessel 70;

FIG. 109 shows a side elevation, cross sectional view of an apparatusthat is arranged to automatically measure and slice portions of meatprimals that have been molded to a predetermined profile correspondingwith a temperature controlled conduit 81 of similar profile,pre-conditioned and tempered primal cuts of boneless meat 87 are locatedin an entry end of conduit 81 followed by a plug such as 82,electromagnetic driving fixtures 83 are arranged to intermittently driveand by magnetic bonding to each plug, carry plugs such as 81, in aforward direction and a distance equal to the selected thickness of asingle slice of beef, blade 92 is controlled to intermittently sliceduring a single revolution shaft 91, conveyor 94 is mounted in anenclosure 98, and adjacent to the exit end of conduit 81, so as toconveniently carry slices to a further processing or packing station;

FIG. 110 shows a cross-sectional view of an apparatus portion of FIG.109 taken along line 110;

FIG. 111 shows a cross-sectional view of an apparatus portion of FIG.109 taken along line 111;

FIG. 112 shows a cross-sectional view of a finished package constructedaccording to the present invention;

FIG. 113 shows a perspective view of a finished package constructedaccording to the present invention;

FIG. 114 shows a perspective view of a tray with flaps constructedaccording to the present invention;

FIG. 115 shows a cross-sectional view of a tray portion including flapsof FIG. 114;

FIG. 116 shows a cross-sectional view of a tray constructed according tothe present invention;

FIG. 117 shows a perspective view of a tray with a flap constructedaccording to the present invention;

FIG. 118 shows a cross-sectional view of packages stacked atop oneanother, constructed according to the present invention;

FIG. 119 shows a top plan view of a tray constructed according to thepresent invention;

FIG. 120 shows a cross-sectional view of a tray portion of FIG. 119;

FIG. 121 shows a cross-sectional view of a tray portion of FIG. 119;

FIG. 122 shows a cross-sectional view of a plurality of stacked trayswith flaps, constructed according to the present invention;

FIG. 123 shows a cross-sectional view of a tray with a flap constructedaccording to the present invention;

FIG. 124 shows a cross-sectional view of a finished package constructedaccording to the present invention;

FIG. 125 shows a cross-sectional view of a master container containingfinished packages constructed according to the present invention;

FIG. 126 shows a perspective view of a tray portion constructedaccording to the present invention;

FIG. 127 shows a cross-sectional view of a tray portion of FIG. 126;

FIG. 128 shows a cross-sectional view of stacked trays in a mastercontainer constructed according to the present invention;

FIG. 129 shows a cross-sectional view of a finished package with a flapconstructed according to the present invention;

FIG. 130 shows a cross-sectional view of a tray with flap constructedaccording to the present invention;

FIG. 131 shows a top plan view of a tray portion with flap constructedaccording to the present invention;

FIG. 132 shows a side plan view of a tray portion of FIG. 131;

FIG. 133 shows a side plan view of stacked trays according to thepresent invention;

FIG. 134 shows a top plan view of a tray portion with flaps constructedaccording to the present invention;

FIG. 135 shows a perspective view of a tray portion with the flapsfolded down according to the present invention;

FIG. 136 shows a cross-sectional view of a tray portion of FIG. 135taken along line 136;

FIG. 137 shows a cross-sectional view of a tray with flaps constructedaccording to the present invention;

FIG. 138 shows a cross-sectional view of a tray with flaps containingiron particles constructed according to the present invention;

FIG. 139 shows a cross-sectional view of a tray portion of FIG. 138;

FIG. 140 shows a schematic view of an apparatus for applying ironparticles according to the present invention;

FIG. 141 shows a cross-sectional view of an apparatus portion of FIG.140;

FIG. 142 shows a cross-sectional detailed view of an apparatus portionof FIG. 141;

FIG. 143 shows a schematic view of an apparatus for applying ironparticles according to the present invention;

FIG. 144 shows a top plan view of a web material containing ironparticles according to the present invention;

FIG. 145 shows a cross-sectional view of the web of FIG. 144 taken alongline 145;

FIG. 146 shows a schematic view of an apparatus for packaging andforming holes in web materials according to the present invention;

FIG. 147 shows a side plan view of a tray formed by the apparatus ofFIG. 146;

FIG. 148 shows a schematic view of a master container sealing apparatusaccording to the present invention;

FIG. 149 shows a perspective view of an apparatus portion of FIG. 148;

FIG. 150 shows a cross-sectional view of an apparatus portion of FIG.149 taken along line 150;

FIG. 151 shows a schematic view of a packaging, labeling, and weighingapparatus according to the present invention;

FIG. 152 shows a top plan view of the apparatus of FIG. 151;

FIG. 153 shows a top plan view of a register formed according to thepresent invention;

FIG. 154 shows a cross-sectional view of a vacuum chamber constructedaccording to the present invention;

FIG. 155 shows a cross-sectional view of an apparatus portion accordingto the present invention;

FIG. 156 shows a cross-sectional view of a vacuum chamber constructedaccording to the present invention;

FIG. 157 shows a cross-sectional view of a tray with flaps according tothe present invention;

FIG. 158 shows a cross-sectional view of a tray portion with flap ofFIG. 157;

FIG. 159 shows a cross-sectional view of a sealing plate constructedaccording to the present invention;

FIG. 160 shows a top plan view of a sealing plate according to thepresent invention;

FIG. 161 shows a top plan view of a sealing plate according to thepresent invention;

FIG. 162 shows a cross-sectional view of the sealing plate of FIG. 161taken along line 162;

FIG. 163 shows a cross-sectional view of a finished package constructedaccording to the present invention;

FIG. 164 shows a cross-sectional view of a tray located in a sealingplate according to the present invention;

FIG. 165 shows a top plan view of a sealing plate according to thepresent invention;

FIG. 166 shows a schematic view of tray walls being bonded when locatedin the sealing plate according to the present invention;

FIG. 167 shows a cross-sectional view of a vacuum chamber constructedaccording to the present invention;

FIG. 168 shows a schematic view of an apparatus for loading and sealingtrays according to the present invention;

FIG. 169 shows a schematic view of an apparatus for forming a laminatedweb according to the present invention;

FIG. 170 shows a schematic view for an apparatus for packaging traysusing a laminated web according to the present invention;

FIG. 171 shows a cross-sectional view of a web material according to thepresent invention;

FIG. 172 shows a schematic view of a packaging and sealing apparatusconstructed according to the present invention;

FIG. 173 shows a cross-sectional view of a tray with a laminated web;

FIG. 174 shows a cross-sectional view of a tray with a single web;

FIG. 175 shows a schematic view of an apparatus for forming mastercontainers according to the present invention;

FIG. 176 shows a cross-sectional view of the apparatus of FIG. 175 takenalong line 176;

FIG. 177 shows a cross-sectional view of an apparatus portion of FIG.175 taken along line 177;

FIG. 178 shows a cross-sectional view of an apparatus portion of FIG.176;

FIG. 179 shows a finished package enclosed within a master container;

FIG. 180 shows an apparatus for grinding and processing meat constructedaccording to the present invention;

FIG. 181 shows an apparatus for grinding and processing meat constructedaccording to the present invention;

FIG. 182 shows a cross-sectional view of an apparatus portion of FIG.181;

FIG. 183 shows a cross-sectional view of an apparatus portion of FIG.181;

FIG. 184 shows a front plan view of a manifold constructed according tothe present invention;

FIG. 185 shows a side plan view of the manifold of FIG. 184;

FIG. 186 shows a cross-sectional view of an apparatus for grinding andprocessing meat according to the present invention;

FIG. 187 shows a cross-sectional view of an apparatus for processingmeat constructed according to the present invention;

FIG. 188 shows a side plan view of an apparatus portion of FIG. 187;

FIG. 189 shows a cross-sectional view of an apparatus portion of FIG.188 taken along line 189;

FIG. 190 shows a cross-sectional view of an apparatus portion of FIG.187 taken along line 190;

FIG. 191 shows a top plan view of a tube structure according to thepresent invention;

FIG. 192 shows a cross-sectional view of an apparatus portion havingthree meat processing tubes, constructed according to the presentinvention;

FIG. 193 shows a cross-sectional view of an apparatus for grinding andprocessing meat;

FIG. 194 shows a cross-sectional view of an apparatus portion of FIG.187;

FIG. 195 shows a cross-sectional view of a measuring device constructedaccording to the present invention;

FIG. 196 shows a top plan view of a packaging and slicing apparatushaving a tunnel, constructed according to the present invention;

FIG. 197 shows a cross-sectional view of the apparatus of FIG. 196 takenalong line 197;

FIG. 198 shows a schematic view of a meat processing apparatusconstructed according to the present invention;

FIG. 199 shows a schematic view of a meat processing and packagingapparatus constructed according to the present invention;

FIG. 200 shows a schematic view of a meat processing and packagingapparatus constructed according to the present invention;

FIG. 201 shows a schematic view of a meat processing and packagingapparatus constructed according to the present invention;

FIG. 202 shows a cross-sectional view of a web material constructedaccording to the present invention;

FIG. 203 shows a perspective view of an over wrapping web materialconstructed according to the present invention;

FIG. 204 shows a perspective view of an over wrapped package constructedaccording to the present invention;

FIG. 205 shows a schematic view of an apparatus portion constructedaccording to the present invention;

FIG. 206 shows a top plan view of an apparatus portion constructedaccording to the present invention;

FIG. 207 shows a cross-sectional view of a meat blending apparatusconstructed according to the present invention;

FIG. 208 shows a cross-sectional view of the meat blending apparatus ofFIG. 207 taken along line 208;

FIG. 209 shows a schematic view of a meat processing and conditioningapparatus constructed according to the present invention;

FIG. 210 shows a cross-sectional view of a meat forming and shapingapparatus constructed according to the present invention;

FIG. 211 shows a side plan view of an apparatus portion of FIG. 210;

FIG. 212 shows a perspective view of a meat forming and shapingapparatus constructed according to the present invention;

FIG. 213 shows a schematic view of a master container sealing apparatusconstructed according to the present invention;

FIG. 214 shows a cross-sectional view of the apparatus of FIG. 212;

FIG. 215 shows a cross-sectional view of a meat forming and shapingapparatus constructed according to the present invention;

FIG. 216 shows a side plan view of an apparatus portion of FIG. 215;

FIG. 217 shows a cross-sectional view of a forming and shaping apparatusfor several primals, constructed according to the present invention;

FIG. 218 shows a cross-sectional view of an apparatus portion of FIG.216;

FIG. 219 shows a cross-sectional view of an apparatus portion of FIG.218;

FIG. 220 shows a cross-sectional view of an apparatus portion forforming and shaping meat primals constructed according to the presentinvention;

FIG. 221 shows a cross-sectional view of an apparatus portion forshaping and forming meat primals constructed according to the presentinvention;

FIG. 222 shows a schematic view of an equipment layout constructedaccording to the present invention;

FIG. 223 shows a cross-sectional view of a master container vacuumchamber constructed according to the present invention;

FIG. 224 shows a schematic view of an equipment layout constructedaccording to the present invention;

FIG. 225 shows a cross-sectional view of a tube apparatus of FIG. 224taken along line 225;

FIG. 226 shows a perspective view of a spool for storing web materialconstructed according to the present invention;

FIG. 227 shows a schematic view of a thermoforming oven of FIG. 224taken along line 227;

FIG. 228 shows a schematic view of equipment layout constructedaccording to the present invention;

FIG. 229 shows a cross-sectional view of a web material constructedaccording to the present invention;

FIG. 230 shows a cross-sectional view of a web material constructedaccording to the present invention;

FIG. 231 shows a detailed view of web material constructed according tothe present invention;

FIG. 232 shows a detailed view of web material constructed according tothe present invention;

FIG. 233 shows a detailed view of web material constructed according tothe present invention;

FIG. 234 shows a detailed view of web material constructed according tothe present invention;

FIG. 235 shows a detailed view of web material constructed according tothe present invention;

FIG. 236 shows a detailed view of web material constructed according tothe present invention;

FIG. 237 shows a detailed view of web material constructed according tothe present invention;

FIG. 238 shows a perspective view of a tray treatment apparatusconstructed according to the present invention;

FIG. 239 shows a perspective view of a tray treatment apparatusconstructed according to the present invention;

FIG. 240 shows a cross-sectional view of a tray forming apparatusconstructed according to the present invention;

FIG. 241 shows a cross-sectional view of a tray forming apparatusconstructed according to the present invention;

FIG. 242 shows a cross-sectional view of web material constructedaccording to the present invention;

FIG. 243 shows a cross-sectional view of web material constructedaccording to the present invention;

FIG. 244 shows a cross-sectional view of a web material constructedaccording to the present invention;

FIG. 245 shows a cross-sectional view of a web material constructedaccording to the present invention;

FIG. 246 shows a cross-sectional view of a web material constructedaccording to the present invention;

FIG. 247 shows a cross-sectional view of formed web material constructedaccording to the present invention;

FIG. 248 shows a cross-sectional view of formed web material constructedaccording to the present invention;

FIG. 249 shows a cross-sectional view of a web material constructedaccording to the present invention;

FIG. 250 shows a cross-sectional view of a web material constructedaccording to the present invention;

FIG. 251 shows a perspective view of a tray portion with ribsconstructed according to the present invention;

FIG. 252 shows a cross-sectional view of formed web material constructedaccording to the present invention;

FIG. 253 shows a cross-sectional view of formed web material constructedaccording to the present invention;

FIG. 254 shows a cross-sectional view of a web forming apparatusconstructed according to the present invention;

FIG. 255 shows a cross-sectional view of a web forming apparatusconstructed according to the present invention;

FIG. 256 shows a cross-sectional view of a web material constructedaccording to the present invention;

FIG. 257 shows a cross-sectional view of a web aperture formingapparatus constructed according to the present invention;

FIG. 258 shows a cross-sectional view of a web forming apparatusconstructed according to the present invention;

FIG. 259 shows a top plan view of an apparatus portion of FIG. 258;

FIG. 260 shows a cross-sectional view of a formed web materialconstructed according to the present invention;

FIG. 261 shows a cross-sectional view of a pressure chamber for removingoxygen from the cell structure of EPS foam constructed according to thepresent invention;

FIG. 262 shows a cross-sectional view of an apparatus for removingoxygen within the cell structure of EPS foam constructed according tothe present invention;

FIG. 263 shows a perspective view of an apparatus portion of FIG. 261;

FIG. 264 shows a front plan view of the apparatus of FIG. 262;

FIG. 265 shows a schematic view of an apparatus with vacuum tubesconstructed according to the present invention;

FIG. 266 shows a schematic view of equipment layout constructedaccording to the present invention;

FIG. 267 shows a schematic view of equipment layout constructedaccording to the present invention;

FIG. 268 shows a tray with flaps having crests and indentationsconstructed according to the present invention;

FIG. 269 shows a perspective view of the tray of FIG. 268 with the flapsopened upward;

FIG. 270 shows a side plan view of stacked trays of FIG. 268 showing aspace between the crest and a flap indentation;

FIG. 271 shows a perspective view of a tray with flaps constructedaccording to the present invention;

FIG. 272 shows a perspective view of the tray of FIG. 271 with the flapsfolded downward;

FIG. 273 shows a cross-sectional view of a tray portion with substanceslocated within a flap space constructed according to the presentinvention;

FIG. 274 shows a cross-sectional view of a tray with flaps having flapspaces;

FIG. 275 shows a schematic representation of an apparatus for processingfresh meat such as ground beef;

FIG. 276 shows a schematic representation of a cross section through aconveyor and packaging tray with goods;

FIG. 277 shows a perspective view of a tray with flaps constructedaccording the present invention;

FIG. 278 shows a cross section of the tray of FIG. 277 through a wallafter the corresponding flap has been folded inwardly;

FIG. 279 shows a perspective view of a mold comprising an extruded tubeof any suitable cross sectional profile having parallel sides with endplugs that are arranged to fit within the extruded tube so as to slidereadily in a gas tight manner;

FIG. 280 shows the profile of this particular extruded molding tube withmeat portion loaded therein;

FIG. 281 shows a detail of a section of the assembled and loadedextruded tube with an end plug in position;

FIG. 282 shows a view of a pre-form web that can be either thermoformedor injection molded from any suitable plastics material such aspolypropylene;

FIG. 283 shows a cross sectional view of the pre-form of FIG. 282;

FIG. 284 shows a cross sectional view of a finished package using thepre-form of FIG. 282;

FIG. 285 shows a prespective view of a pre-form web with corrugatedcorners constructed according to the present invention;

FIG. 286 shows a perspective view of a portion of a finished trayconstructed from the pre-form web of FIG. 285;

FIG. 287 shows a schematic illustration of a representative portion ofthe Internet for transacting commerce according to the presentinvention;

FIG. 288 shows a block diagram of the several components of a sellerserver shown in FIG. 287 that is used to store a database and controlprogram for servicing buyers;

FIG. 289 shows a block diagram of the several components of a buyercomputer shown in FIG. 285 that are used to store and implement certainportions of the database and control program;

FIG. 290 shows a block diagram of a method of transacting commerce overa communications system according to the present invention;

FIG. 291 shows a schematic illustration of an embodiment of a plantlayout according to the present invention;

FIG. 292 shows a schematic illustration of an embodiment of a traypackaging layout according to the present invention;

FIG. 293 shows a schematic illustration of an embodiment of traytreatment and finishing equipment according to the present invention;

FIG. 294 shows a perspective view of a tray portion with flaps havingthe flap ends contoured to fold overlapping the tray corners;

FIG. 295 shows a perspective view of the tray portion of FIG. 294 withthe flap ends bonded to the tray corners;

FIG. 296 shows a schematic illustration of an embodiment of a plantlayout according to the present invention;

FIG. 297 shows a schematic illustration of a section of the plant forpackaging trays with meat products;

FIG. 298 shows a sectional view of the tray de-nesting apparatus portionof FIG. 297 before the flap ends have been bonded to the tray walls;

FIG. 299 shows a schematic illustration of an embodiment of an apparatusfor forming webs according to the present invention; and

FIG. 300 shows a schematic illustration of the web material of FIG. 299.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

As used herein, the following terms take the following mean, unlessotherwise indicated.

The term “case ready” refers to retail packaged fresh meats (that weretypically formerly prepared at the supermarket) that has been packagedready for retail sale from the meat case at a place of production remotefrom the supermarket.

The term “high oxygen modified atmosphere” refers to a blend of gasesthat includes some or all of the naturally occurring atmospheric gasesbut in proportions that are different to air and including a high levelof oxygen which may be greater than 40%. Such an example would be a gascomprising 80% oxygen and 20% carbon dioxide, however in virtually allapplications a residual quantity of nitrogen remains in the sealed “highoxygen modified atmosphere” package.

The term “low oxygen” or “no oxygen” modified atmosphere” refers to ablend of gases that includes some or all of the naturally occurringatmospheric gases (except oxygen) but in proportions that are differentto air and including a low (or zero level of oxygen) which may be lessthan 300-500 parts per million.

The term “MAP” refers to modified atmosphere packaging.

The term “CAP” refers to controlled atmosphere packaging.

The term “Epsilon GMS-40” or “GMS-40” refers to an apparatus that can beused to measure the fat and/or lean content of pumpable ground meats.The GMS-40 is manufactured and supplied by Epsilon Industries, ofAustin, Tex. Additional information is available on web site:www.epsilon-gms.com.

The term “AVS-ET system” refers to a system that can be used to identifythe composition of boneless meats. The system can identify quantities offat, muscle/lean tissue, contaminants, bone, metal inclusions and othermatter that is transferred, in a continuous stream, through a conduitand into and then away from the AVS-ET system. The system operatespreferably when the continuous stream is exclusive of any voids such aspockets of air. The system is manufactured and supplied by Holmes NewmanAssociates, 4221 Fallsbrae Road, of Fallbrook, Calif. 92028.

The term “statiflo blending devices” refers to a continuous, static andenclosed material blending device that can introduce gases such as CO₂to the blended material. STATIFLO is a registered trademark of StatifloInternational, The Crown Center, Bond Street, Macclesfield, Cheshire SKI16QS, UK. Information is available on web site: sales@statiflo.co.uk.

The term “blending devices” refers to a continuous, static and enclosedmaterial blending device that can be used to continuously blend suchperishable goods as ground meats that comprise substantially twocomponents of fat and lean meat and may also be used to introduce gasessuch as CO₂ to the blended materials.

The term “shelf life” refers to the period of time between the date ofretail packaging of perishable goods (that are slowly deteriorating) ofacceptable quality and a subsequent point in time or date, prior to theperishable goods having deteriorated to an unacceptable condition.

The term “PP” refers to polypropylene.

The term “EPS” refers to expanded polystyrene.

The term “pPVC” refers to plasticized polyvinylchloride.

The term “PET,” polyester or “APET” refers to amorphous polyethyleneterephthalate.

The term “heat activated adhesives (or coating)” refers to adhesivesthat become active and capable of bonding substances together whenheated to a suitable temperature that otherwise, at ambient temperature,will not bond.

The term “OTR” refers to oxygen transmission rate.

The term “perishable goods” or “goods” refers to any perishable foodssuch as sliced beef or other fresh meats, ground meats, poultry piecesetc.

The term “liquids and oils” refers to water, liquids, blood, purge,liquid animal fats and oils and the like.

The term “master container” generally refers to a substantially gasbarrier container that can be filled with finished packages, evacuatedof substantially all atmospheric air and filled with any suitable gas.However, said “master container” may also be gas permeable if sodesired.

The terms “suitable substance”, “suitable gas” or “suitable gases” referto any gas or blend of gasses, provided at any pressure (suitablepressure) such as 45% oxygen and 55% carbon dioxide at ambient pressureor any other blend of gases. A suitable gas may include a blend ofcarbon dioxide and nitrogen and oxygen with residual atmospheric gasesin any relative proportions. Examples are provided, but are notrestricted to any of the following:

1. A blend of gases including argon, carbon dioxide, nitrogen and aquantity of oxygen that does not exceed 5% and is not less than 5 PPM(parts per million).

2. Air that has been filtered to remove substantially all oxygentherefrom.

3. Carbon dioxide and nitrogen in any relative proportions.

4. Carbon dioxide and oxygen where oxygen does not exceed 5% and is notless than 5 PPM.

5. Carbon dioxide and a quantity of oxygen that does not exceed 5% andis not less than 5 PPM (parts per million).

6. Nitrogen and a quantity of oxygen that does not exceed 5% and is notless than 5 PPM (parts per million).

7. A blend of inert gasses and a quantity of oxygen that does not exceed5% and is not less than 5 PPM (parts per million).

8. A blend of pentane and nitrogen in any relative proportions and aquantity of oxygen that does not exceed 5% and is not less than 5 PPM(parts per million).

9. A blend of propane and nitrogen in any relative proportions and aquantity of oxygen that does not exceed 5% and is not less than 5 PPM(parts per million).

10. A blend of butane and nitrogen in any relative proportions and aquantity of oxygen that does not exceed 5% and is not less than 5 PPM(parts per million).

11. A blend of a CFC and nitrogen in any relative proportions and aquantity of oxygen that does not exceed 5% and is not less than 5 PPM(parts per million).

12. A blend of an HCFC and nitrogen in any relative proportions and aquantity of oxygen that does not exceed 5% and is not less than 5 PPM(parts per million).

13. A blend of methane and nitrogen in any relative proportions and aquantity of oxygen that does not exceed 5% and is not less than 5 PPM(parts per million).

14. A blend of hydrogen sulfide and nitrogen in any relative proportionsand a quantity of oxygen that does not exceed 5% and is not less than 5PPM (parts per million).

15. A blend of carbon monoxide and nitrogen in any relative proportionsand a quantity of oxygen that does not exceed 5% and is not less than 5PPM (parts per million).

16. A blend of sulfur dioxide and nitrogen in any relative proportionsand a quantity of oxygen that does not exceed 5% and is not less than 5PPM (parts per million).

17. A gas including 100% carbon dioxide

18. A substance or agent including one or more of the following:isoascorbic acid, ascorbic acid, citric acid, erythorbic acid, lacticacid, succinic acid or mixtures of salts thereof. Glycerol monolaurate,potassium sorbate, sodium sorbate, sodium iodoacetate, potassiumacetate, iodoacetomide, potassium iodoacetate, sodium acetate ormixtures or acidic solutions thereof.

The term “suitable gas pressure” or “water pressure” refers to anypressure that is suitable for the application and may be controlledwithin any of the following pressure ranges, or any other suitablepressure:

Suitable gas pressure:

gas at a pressure of 1 PSI to 14 PSI.

gas at a pressure of up to 13 PSI.

gas at a pressure of 13 PSI to 50 PSI.

gas at a pressure of 50 PSI to 80 PSI.

gas at a pressure of 80 PSI to 120 PSI.

gas at a pressure of 120 PSI to 200 PSI.

gas at a pressure of 200 PSI to 500 PSI.

gas at a pressure above 500 PSI.

Suitable water pressure:

water at a pressure of 1 PSI to 14 PSI.

water at a pressure of up to 13 PSI.

water at a pressure of 13 PSI to 50 PSI.

water at a pressure of 50 PSI to 80 PSI.

water at a pressure of 80 PSI to 120 PSI.

water at a pressure of 120 PSI to 200 PSI.

water at a pressure of 200 PSI to 500 PSI.

water at a pressure above 500 PSI.

The term “suitable gas temperature” or “suitable water temperature”refers to any temperature that is suitable for the application and maybe controlled within any suitable temperature ranges for any suitableperiod of time, or at any other suitable temperature. Suitabletemperature also includes a temperature range which may be apasteurizing temperature range such as maintaining a product such as abeef primal within a temperature range of not less than 138.5 degrees F.to 140 degrees F. and for a suitable period of time.

Bond or Bonding refers to sealing or welding of two or more surfacestogether by any suitable means such as with any suitable adhesive, RFwelding, ultrasonic welding heat sealing, or any other suitable means.

Hermetic seal refers to a seal or bonding of two or more surfaces of anysuitable material together by any suitable means to provide an enclosedspace and wherein said enclosed space is rendered fully enclosed in sucha manner that will substantially inhibit the passage or communication ofany substance such as gas, air or liquids from within said enclosedspace to and with the exterior of said enclosed space.

Pre-Form refers to a thermoformed or suitably fabricated packagingcomponent that has been arranged with one or more hinged flaps that canbe folded or bonded to produce a useful packaging tray or container forgoods. Pre-forms may also comprise more than one component that aresubsequently assembled together to provide one or more components butwhere the number of items remaining after assembly are less than thenumber of components from which the remaining items are produced.

“Valve” refers to any suitable valve to suit the particular needs of thedisclosed application. Valves may be arranged to control the flow ofgas, liquid, or solids such as powders and can be selected frommanufacturers skilled in the arts of valve manufacturing of anyparticular valve from any suitable materials.

“CPU” refers to a central processing unit or any suitable computerprocessor suitable for the application such as are contained in mostpersonal computers (PC).

“HHRCD” refers to a hand held remote controlling device such as a PALMPILOT®.

“Fat” content is a component of meat and may mean the measured fatcontent of a quantity of boneless meat harvested from any species ofslaughtered animal such as beef.

“Meat” can mean any meat harvested from any species of slaughteredanimal wherein the meat comprises several components but generallyincluding water, fat, oils, and protein in relative quantities that arenot precisely known at the time of harvesting and must be measured todetermine the precise ratio of each component.

Trays with Peelable Lids

In accordance with the present invention, trays having peelable lids aredisclosed herein. Perishable goods packaged in trays with peelable lidshave extended shelf life. A peelable lid provides a method of delayingthe exposure of fresh meat contained within a package to ambient air ata predetermined period, preferably at the point of sale.

Referring first to FIGS. 1, 2, and 3, a preferred package 100 made inaccordance with the present invention includes a tray 102 into whichmeat 104 (FIG. 3) or other perishable food product is placed. A firstlayer 106 and second layer 108 of heat sealable material are then placedover the tray 102 and heat sealed to the upper horizontal flange 110that extends outwardly from the upper periphery of the tray 102. Bydraftsman's license used in accordance with the present invention, thelayers 106 and 108 are shown separated. In actuality, they are inintimate contact throughout their entire length and width. The layers106 and 108 are also shown to be heat sealed to each other by crosshatching shown in the drawings at locations 112 between the two layersand between the bottom layer 106 and the tray flange 110. In actualityagain, there is no substantial thickness at the heat sealed locations,but in fact, the materials are in intimate contact with each otherand/or the flange 110 of the tray 102. Thereby substantiallyexpelling/removing air or gas from therebetween.

Depending upon the particular design and use of the tray, the firstlayer 106 can be composed of a substantially gas impermeable barrierlayer or a substantially gas permeable layer. Similarly, the outer layer108 can either be substantially gas impermeable or permeable.Substantially gas permeable materials include plasticized polyvinylchloride (pPVC) and polyethylene (PE). Preferably, these are moretypically used in thicknesses from 0.0004 inches to 0.001 inches.Preferably, suitable barrier layers (substantially gas impermeable) arecomposed of amorphous polyethylene terephthalate (APET) unplasticizedpolyvinyl chloride (uPVC) and a composite material such as a biaxiallyoriented polyester/tie/polyvinylidene chloride/tie/polyethylene. Othersuitable materials known to those of ordinary skill can also be employedin accordance with the present invention. The trays are preferably madeof polyester (APET, amorphous polyethylene terephthalate often referredto as polyester), polyvinyl chloride or other suitable food gradepolymers. As used herein, a web is a sheet of material that may have oneor a plurality of layers or zones of differing compositions. Also, whenthe terms “substantially gas permeable” or “substantially gasimpermeable” are used, they are intended to reflect the fact that nopractical heat sealable material is totally gas permeable orimpermeable. Materials disclosed herein as substantially gas impermeablewill serve as a barrier layer to the transfer of significant amounts ofgas over time. Likewise substantially gas permeable materials will notfunction as a barrier but will allow ready diffusion of gastherethrough.

Method for Producing Peelable Lids

A method is disclosed for producing the peelable lids disclosed abovewhich include a label.

Referring now to FIG. 4, a side elevation of a package sealingarrangement for assembling a package of the type disclosed in FIG. 1 isshown. Trays 102 are loaded with perishable edible material 104 andplaced in conventional carrier plates on a conveyor (not shown) andconveyed toward a heat sealing station 114. A roll 116 of heat sealablematerial is supplied above the conveyor. The sheet of material that willbecome the inner web 106 from the roll 116 travels downwardly and wrapsaround a roller 118 and then traverses horizontally in a left-to-rightdirection along with the trays 102 being conveyed by a conveyor (notshown). A label dispenser 118 positions a label 120 on the upper surfaceof the inner web 106 of heat sealable material. The outer web 108 ofsheet material is then drawn from roll 122 downwardly around anotherroller 124 and traverses horizontally from left-to-right, where thelabel 120 is captured between the inner and outer webs 106 and 108. Thetwo webs and the label are then run through a pair of nip rolls 126 tocause the two webs and the label to come into intimate contact and alsosubstantially removing air from between the webs. The webs of heatsealable material 106 and 108 are then positioned at the heat sealingstation 114. Corresponding tray 102 is positioned in the lower portion114 of the heat sealing chamber. The lower portion of the heat sealingchamber 162 is then raised upwardly toward the upper portion 160 of theheat sealing chamber wherein the webs 106 and 108 are sealed to eachother and to the upper surface of the flange/lip portion of the tray 102around the periphery at the flange. At the same time, a knifeincorporated into the mechanism trims the excess material neatly aroundthe outer edge of the tray flange 110. The scrap material 128 is thenpassed around a roller 130 and onto a scrap retrieval roll 132. The tray102 is then moved onto another conveyor where the finished packages 134are moved from left to right to a transportation and/or storage station.

Apparatus for Forming Peelable Lids

Referring to FIGS. 42-44, a schematic side elevation view through asection of a package is shown. A schematic view is provided so as toclearly disclose an example of a preferred peelable seal mechanism thatwill facilitate peeling of the third web from the package while thesecond web remains substantially intact and sealed to the first web. Theexample is provided to show preferred plastics materials that will sealas required when used according to the present invention. Other selectedmaterials may also be used in similar manner without departing from thegeneral ambit of this invention. First 1002, second 1004, and third 1006webs are shown where, in this instance, first web 1002 preferablyincludes a thermoformed tray produced from a multilayer co-extrudedmaterial including first, outer layer 1088 of Eastman 9921 about 0.008″thick and a second inner layer 1086, about 0.004″ thick, including ablend of about 50% PETG 6763 and about 50% Eastman 5116 (or EastmanPM14458 or equivalent shown in FIG. 42). Second web 1004 preferablyincludes a web of pPVC with a thickness of about 0.0008″. Referring toFIG. 41, third web 1006 preferably includes a two layer co-extruded webwith a first outer layer 1082 of Eastman PET 9921 about 0.003″ inthickness and a second inner layer 1084 about 0.003″ thick including ablend of about 16% Eastman PETG 6763 and about 84% Eastman PET 9921.Referring now to FIG. 40, preferably, a water cooled clamp 1104 is shownin position above the flanges of first, second and third webs and twoseparate heat seal bars 1106 and 1008 are arranged adjacent thereto andall are separated by space and are each independently activated andcontrolled and moved. Preferably, heat seal bar 1106 can have a settemperature of about 385 degrees F. and heat seal bar 1108 can have aset temperature of about 370 degrees F. Third web second inner layer1084 will heat seal to second web when the temperature at the interfaceof second and third webs reaches about 385 degrees F. and above.Preferably, second web will heat seal to second inner layer 1086 offirst web 1002 when the temperature of the interface between the firstand second webs is about 370 degrees F. and above.

Preferably, the water cooled clamp 1104 is mounted to an independentlyactivated pneumatic driver, providing downward pressure such that thewater cooled clamp can clamp against first, second and third webs so asto hold them firmly against the rubber seal 1110 located beneath thefirst web flange portions 1072 and 1074. Preferably, heat seal bars 1106and 1108 are independently attached to pneumatic drivers for applyingpressure thereto so as to facilitate a method to seal third, second andfirst webs together under independently selected pressure. Preferably,heat seal bar 1106 heat seals the third, second and first webs togetherat 1112 and 1114 and heat seal bar 1108 heat seals the second web 1004to the first web 1002 at 1116 but does not heat seal the interfacebetween the third 1006 and second 1004 webs. When the package isassembled and sealed in the foregoing manner, the third web 1006 can bepeeled from the package without rupturing the second web 1004.Preferably, second web 1004 may be perforated so that after seals 1112,1114 and 1116 have been provided, the second 1004 and third 1006 webscan be separated to provide a space 1118 therebetween.

Seals at 1112, 1114, and 1116 have been shown as heat seals, however,effective sealing can be achieved with use of ultra sonic devices oralternatively latex rubber adhesives when applied at the interfaces ofthe webs at 1112, 1114, and 1116, or with any other suitable method ofsealing. Such sealing can provide improved economics while stillproviding an effective peeling mechanism as required and describedabove.

Stackable Trays, Trays with Valves

Conventional thermoformed trays are shaped in a mold which have sidesthat generally are inclined to facilitate separation between the moldand the tray. Thus, making them cumbersome to stack when filled, becausethe smaller area at the bottom cannot be suitably supported by thelarger opening at the top. Trays constructed according to the presentinvention include members, in the form of flaps that provide a suitableresting area for the lower portion of the tray when stacked atop oneanother.

Embodiment 1

Referring now to FIGS. 7-9, a preferred embodiment of a stackable tray200 constructed in accordance with the present invention is illustrated.Referring first to FIGS. 7 and 8, a tray 202 has a recessed bottom 204so as to form peripheral legs 206 on which the tray rests. Thelongitudinal edges of the tray each include a flange 208. The outerflange 208 is coupled to an inner flange 210 of the tray by a hingemember 212. The inner flange is integral with and extends outwardly fromthe upper edge of the tray 202. A recessed platform 214 is formed acrossthe corner of the tray at diagonal corners of the tray. The bottom ofthe platform 214 is lowered slightly relative to the level of innerflange 210. The platform 214 in the edge of the tray carries a smalldepression 216, the bottom of which is perforated. During evacuation andflushing, gases can rapidly enter through the perforation in thedepression 216, travel through the recess formed by platform 214 intothe interior of the tray and vice versa. Adjacent to the recessedplatform 214, the flange 208 includes an outwardly extended flap 218. Inthe unfolded position shown in FIG. 7, the flap carries a concave dimple220 (viewed from the top). The dimple is located relative to the hinge212 such that when the flange 208 is folded over on top of the flange210, the dimple 220 resides directly above and central to the depression216. When desired, the dimple can be depressed from the upper side so asto reverse its concavity. When the concavity is reversed, it extendsdownwardly into depression 216 to close off the perforation in thecavity and thus seal the container.

Referring now to FIG. 8, a first and second web 222 and 224,respectively, of heat sealable material overlay the upper portion of thetray 202 and are heat sealed to the upper surface of the flange 210.First web 222 may be incorporated by deleting web 222. A label 226 orother indicia bearing material can be sandwiched between the heatsealable layers 222 and 224. The method for incorporating a labelbetween a first and second web has been described above.

The label 226 sandwiched between heat sealable webs 222 and 224 isoptional and can cover the entire surface of the tray 202.Alternatively, the label can cover only a portion of the productcontained in the tray. The label can carry graphics that, for example,show the contents in a fully prepared and cooked condition to suggest tothe consumer how the product will look when cooked, yet allowing theconsumer to see at least a portion of the fresh product in the tray. Forexample, if the tray contained fresh beef patties, the label could coverhalf of the exposed upper surface. The label may be arranged with astraight cut or opening running the full length of the package.Alternatively, the label could be positioned on one side of a diagonalthrough the package, while the portion of the package on the oppositeside of the diagonal would be open for viewing the fresh, packagedproduct.

Referring again to FIG. 7, the remainder of the longitudinal extent ofthe flanges 208 include lateral reinforcing ribs 228 that extendupwardly from the flanges 208 when folded over the top of flange 210.The reinforcing ribs 228 have a recess 230 that receives the legs 206 ofan identical container stacked on top of a first container as shown inFIG. 9. The recesses inhibit lateral movement of one tray relative toanother. Thus, these containers are stackable for use for example in themaster bag evacuation technique which will be described below inconjunction with FIG. 5.

Embodiment 2

Referring now to FIGS. 10-13, another embodiment of a stackable tray 300constructed in accordance with the present invention is illustrated. Thetray in plan form is generally rectangularly shaped. The tray includesfirst and second sidewalls 302 and first and second end walls 304. Walls302 and 304 are generally upright and slope inwardly from their upperportion toward the tray bottom 306 to facilitate separation from a mold.The bottom 306 has a raised central portion 308 that slopes downwardlytoward the bottom of each end wall 304. The upper end of the sidewalls302 and end walls 304 terminate in an outwardly extending horizontalflange 310 that extends completely around the tray 300. The raisedcenter portion 308 creates a cavity 312 in the bottom of the tray. Whenthe trays are filled and stacked, the contents extend above the flange310. The cavity 312 will accommodate the raised contents withoutcompression in a stacked arrangement.

Referring to FIGS. 10-13, a horizontal platform 314 is formed indiagonally opposed corners of the tray. The platform 314 is positionedat an elevation slightly below that of flange 310. A wall segment 316extends downwardly from the inner edge 318 of the platform 314 and hasedges that join the sidewalls 302 and end walls 304. The platform 314and the wall 316 form a recess on the outside of the tray. An aperture320 is formed in the center portion of platform 314 and allows gascommunication between the inside of the tray and the outside of the trayvia the recess when a web is sealed over the tray to flange 310.

Referring now to FIGS. 14 and 15, the tray 300 also has movable flanges322 that are hinged via a hinge 324 to the outer edges of the portions310 a of horizontal flanges 310 that extend outwardly from the end walls304. The flange 322 when open carries a hemispherical shaped dimple 326.The center of the dimple 326 is on a line perpendicular to the hinge 324which line also runs through the center of aperture 320. The centers ofthe aperture 320 and the dimple 326 are equidistantly spaced from thehinges. Thus, as shown in FIG. 14, when the movable flange 322 is foldedover the flange 310, the dimple 326 resides over the aperture 320.Referring to FIG. 14, when a web 328 of material is heat-sealed over thetop of the tray 300, the interior of the tray 300 remains open to theatmosphere through the space between platform 314 and web 328 throughaperture 320. As will be better understood below, it is many timesdesirable to close the aperture 320. This is done by pressing downwardlyon the exterior of the dimple 326 forcing it to reverse itself as shownin FIG. 15 and extend downwardly and fill the aperture 320, thus closingit and sealing the inside of the tray 300 from the external atmosphere.

Embodiment 3

Referring now to FIGS. 17 and 18, another embodiment of a stackable traywith tray valve constructed according to the present invention is shown.In this embodiment, a web 400 of substantially gas permeable material isheat sealed at 402 to the top of the peripheral flange 404 of a tray406. A frustoconical tube 408 extends upwardly from ledge 410 andterminates in an opening 412 that is slightly above the level of theouter flange 404. After heat sealing web 400 to the flange 404, the web400 overlying the opening 412 contacts the upper edge of thefrustoconical member thus forming an effective valve to close theinterior of the containers 406 from the atmosphere. During evacuation ofthe master pack, the portion of the web 400 over the frustoconicalmember 408 will elastically extend away from the aperture until the gasinside the package is completely withdrawn, allowing full evacuation ofthe individual container. This occurs because the air/gas pressureinside the package is greater than the air gas pressure outside thepackage 406 during evacuation. When gas flushing occurs, whichimmediately follows evacuation, the web at the opening 412 will again beelastically extended and lifted off the rim of the frustoconical member408. This again occurs because a partial vacuum remains in the recess ofthe dome 414 overlying the frustoconical member. Moreover, during gasflushing, at least the initial pressure in the container is less thanthat on the outside thus allowing gas pressure on the outside to distendthe web 400 away from the opening 412. After equilibration, the tensionof the web 400 over the rim of the frustoconical member 408 remains soas to effectively close it and prevent ingress of undesirable materialinto and/or egress of juice or matter from the container 406.

Embodiment 4

Referring now to FIGS. 20-22, another alternative arrangement for avalve structure similar in operation to that shown in FIGS. 17 and 18includes a tube 700 that extends upwardly from the upper surface ofledge 702. The tube is connected to the ledge 702 by a concentricbellows structure 704 that allows the tube 700 to move upwardly anddownwardly relative to the ledge. In practice, the upper lip of the tube(which forms an opening into the tray from the outside) is in contactwith the web. The dimple 710 resides over the upper edge of the tube700. During evacuation and gas flushing, the web 708 will distend awayfrom the lip 706 of the tube in the same manner as described inconjunction with FIGS. 17 and 18 as shown in FIG. 21. However, the tubemay be more permanently closed by depression and reversal of the dimple710. Full reversal of the dimple 710 would push the tubes 700 downwardlyagainst the resistance of the bellows structure 704 thus, forming a verytight closure between the upper lip 706 of the tube and the bottomsurface of the reversed dimple 710.

Embodiment 5

Referring now to FIG. 6, another embodiment of a tray with valveconstructed in accordance with the present invention is shown. In thisembodiment, the tray 146 has an upper peripheral flange 148 that extendsoutwardly from the entire upper periphery of the tray 146. The traysides extend downwardly to the horizontally disposed bottom. Adownwardly extending recess 150 is cut in the tray corners. The edges ofthe recess 152 communicate with the interior of the tray. At the innerportion of the recess, the recess and the wall of the tray terminate inan opening 154 having its upper edge at the same level as the uppersurface of the flange 148. The opening 154 functions in a similar manneras the apertures in the tray 202 shown in FIG. 7. However, in thisembodiment, if the tray is tipped, undesirable juices can flow into therecess 150 and back out through the edges of the recess 152. In thismanner the undesirable juices/liquids will not easily exit the packagethrough the opening 154.

Trays constructed in accordance with the present invention provide acloseable ventilation mechanism. In addition, trays constructedaccording to the present invention provide for ledges which allow thetrays to be stacked in a convenient fashion in master bag or mastercontainers as shown in FIG. 5. Further, valves according to the presentinvention may be one way only valves.

Master Containers, Master Bags

Packaged trays constructed according to the present invention can bestacked in master containers, evacuated and flushed with desirablegases, and the master container can be sealed to enhance the shelf lifeof the packaged goods.

A description of the master container method of packaging perishablegood according to the present invention will now be described withreference to FIGS. 5, 10-13, and 16.

One of the aforementioned trays make suitable packages for use with themaster container method provided the tray includes foldable flaps andchannels providing communication from the interior of the package to theexterior surrounding environment, for example the tray of FIG. 10.Referring now to FIG. 11, the package can be used to store and transportred meat 330, for example, ground beef. In accordance with the presentinvention, the ground beef 330 may be ground in a conventional grinder.The grinder may be modified so that preconditioned carbon dioxide at apredetermined temperature is injected into the grinder head for twopurposes. The first is to cool the grinder head; the second is to allowthe carbon dioxide to mix with the ground beef 330 and become dissolvedin the liquid therein. The dissolved carbon dioxide will aid inpreservation of the ground beef during the storage period. A web 328 ofsubstantially gas permeable material is then placed over the tray 300and heat sealed to the flange 310 in a conventional manner as shown inFIG. 12. The web is taught over the top of the red meat to prevent itsmovement about the tray during handling. A label 332 may be applied tothe upper surface of the web 328 if desired. Alternatively, a dual webcan be employed as shown in FIG. 1 and a label sandwiched therebetween.Thereafter, the flaps or movable flanges 322 are folded over the top ofthe flange portions 310 a so that the dimples 326 reside over theapertures 320. However, any of the aforementioned trays with valves canbe used. The flaps 322 are then further heat sealed along their outeredges to the flanges 310 at a second heat sealing station to form acompleted package as shown in FIG. 13.

Referring now to FIG. 16, a preferred embodiment of a master containerconstructed according to the present invention is shown. The mastercontainer 334 can be thermoformed from substantially gas barriermaterials such as unplasticized PVC or alternatively a coextrudedmaterial including amorphous polyethylene terephthalate and polyethyleneglycol. The material can be formed with the polyethylene glycol layer onthe inside of the tray allowing exposure to the web of PVC material forheat sealing. The master container 334 includes flange 336 locatedaround the periphery of the upper portion of the container 334. Themaster container containing finished packages 300 with perishable goodstherein are evacuated and flushed with a gas of suitable composition.The master container can be sealed by a web of material to the flange336.

As shown in FIG. 16, a plurality of trays 300 may then be positioned ina master tray 334. For example, in a 3 high by 4 wide array. Inaccordance with the method of the present invention, the master tray 334can then be evacuated and flushed with substantially oxygen free gases.At the same time, the individual packages 300 are evacuated through theapertures 320 and flushed with inert gases that enter the individualpackages through apertures 320 as well. A package formed in accordancewith the present invention allows the use of relatively large aperture320, which in turn enables very rapid evacuation and gas flushing of theindividual packages. With the disclosed system it is estimated that onlya few seconds will be needed to completely evacuate and gas flush themaster tray 334 and individual trays 300. After the containers areevacuated and flushed, a master web 338 is heat sealed to the top of themaster tray 334. To form a completed master tray 334, if desired, anoxygen absorber may be inserted in the master tray 334 so that it isassured that the residual oxygen content in the package will stay belowabout 0.05%. This low level of oxygen is required to preventirreversible oxidation of the deoxymyoglobin in the red meat and formingof metmyoglobin.

Once the package reaches its destination, it can be stored for severaldays in a sealed condition. When it is time to display the meat, themaster web 338 is removed from the master tray 334 and the individualpackages can be weighed and labeled. At that time, oxygen reenters theindividual packages 300 through the aperture 320 as well as through thesubstantially gas permeable web 328. The oxygen converts thedeoxymyoglobin in the red meat to oxymyoglobin, giving the meat a veryfresh red appearance. Before placing the package in the display case,the dimple 326, one embodiment of which is shown in FIGS. 14-15, isdepressed so as to close the aperture 320 which prevents the entry ofundesirable elements such as insects into the package, and alsosubstantially seals the package so that juices from the red meat cannotescape from the container if it is tipped on end.

Referring now to FIG. 5, a preferred alternate master bag containerconstructed according to the present invention is illustrated. Traysconstructed according to the present invention can be stackedconveniently atop one another because the trays have been provided withflaps which fold inwardly to provide a ledge for a tray resting atopanother tray can rest. Once trays are placed inside a master containeras shown in FIG. 5, the gas inside the master bag and trays can beevacuated through opening 140, because trays constructed according tothe present invention include valves which allow the interior of sealedtrays 136 to also be evacuated, and then flushed with a gas of desirablecomposition. The gas is preferably inert and substantially oxygen-freeso as to reduce oxidation of the edible products in the packages 136during storage. The number of cycles which are necessary to lower thelevel of the undesirable gas will vary. Once the master bag reaches anintermediate processing station prior to delivery to the location ofpoint of display, it can be opened and flushed with high oxygenatmosphere containing 80% O₂+CO₂. The packages can be weighed andlabeled. Then the dimples may be depressed to close the perforations indepressions at this station or alternatively left open. In somealternates of the present invention, the trays are provided with one-wayvalves which eliminates the need for dimples. Other alternates of traysmay have no valves, because these packages will have been packaged in alow oxygen atmosphere. After this step, the trays can then be replacedinto a master bag at which time the interior can be partially orcompletely evacuated and flushed with a high oxygen content gas such as80% O₂+CO₂. The master bag can then be heat sealed again. In this way,extra days of shelf life can be obtained because the CO₂ will tend toinhibit bacterial growth.

This method of packaging can be advantageously used for other types ofhigher value products such as tomatoes, grapes, peaches and the like.

Referring again to FIG. 5, an alternative to evacuating the bag 138,includes an oxygen absorber such as an iron compound that can be placedin a container 142 in the master bag 138. Thus, instead of oradditionally to evacuating and flushing with an inert or substantiallyoxygen free gas, the oxygen-absorbing compound quickly absorbs allremaining oxygen in the bag leaving only nitrogen and other inert gasesthat will not adversely affect the condition or value of the food or redmeat products in the containers.

In practice it is possible that all features described above will beincorporated into individual retail package structures. With the valvearrangement, free passage of air and/or gas through the aperture isessentially restricted. In addition, small microperforations in theoverlying web may be employed to allow more rapid gas/air exchange thanwould otherwise occur through a normal substantially gas permeablematerial such as plasticized polyvinyl chloride. Such microperforationswould facilitate more rapid reoxygenation of the deoxymyoglobin andgeneration of a desirable bright red meat color.

Soaker Pads

Soaker pads provide absorptive materials to absorb liquids extruded bythe packaged goods. Soaker pads constructed according to the presentinvention include bacteria sensing materials.

Referring now to FIG. 22, a tray constructed according to the presentinvention is shown. Tray 800 is configured similarly to that of the trayshown in FIG. 10, and carries a soaker pad 802 that lies on the bottomof the tray. A plan side view of soaker pad 802 is shown in FIG. 24 anda cross-sectional view C-C is shown in FIG. 23. The ground beef 804 orother edible material is positioned on the soaker pad and first andsecond webs 806 and 808 of heat sealable material are placed over thetray and sealed to the horizontal flanges 810 that extend outwardly fromthe upper edges of the tray. The label 812 is included of a specialpolymeric material that has the capability of indicating the presence ofE. coli bacteria. This material may be laminated into a three-layer webincluding polypropylene/E. coli sensor material/polypropylene orpolyethylene/sensor material/polyethylene. The polymeric materialemployed is of the type disclosed in the paper entitled “A Litmus Testfor Molecular Recognition Using Artificial Membrane,” Charych, D. et al.Chemistry and Biology, Vol. 3, No. 2, February 1996, 3:113-120,expressly incorporated herein by reference. The lower web 806 may bemicroperforated in the region of the label 812 so that juices from theground beef 804 can penetrate the web and contact the label 812. Thelabel 812 will change color in the presence of E. coli bacteria. Theupper surface of the label can also be treated so that it may be printedwith instructions relating to the E. coli test and/or informationrelating to the ground beef 804 or other edible product. A detail of thewebs 806 and 808 carrying the litmus test label 812 is shown in FIG. 25.

Alternatively, as shown in FIGS. 24 and 25 (a cross-section of FIG. 24along section line c-c) shows that the container for the soaker pad 808can be made of the laminated three-layer web described above containingas the middle layer the litmus test sensor material. In this embodiment,the absorbent material 814 in the soaker pad 802 is encased in an upperweb 816 of the tri-layer test material and a lower web 818 of the sametest material. It is heat sealed around the entire periphery 820 andplaced in the bottom of the tray 800 (FIG. 22). Both webs 816 and 818are microperforated so that juices from the red meat 804 can penetrateto the absorbent layer 814. The presence of E. coli will be shown by achange in color of the test material in the web 816 and 818.

FIG. 26 illustrates a tray 800 similar to that shown in FIG. 22.However, this tray carries a plurality of ground beef patties 822 thatare interleaved with layers 824 of the test material. In this manner,the presence of E. coli bacteria can be ascertained at a variety oflocations in the package.

Apparatus and Methods for the Manufacture of Soaker Pads

Referring to FIGS. 27-30, a side elevation (FIG. 28) and a plan view(FIG. 29) of an apparatus for manufacture of soaker pads with theengineered polymerized molecular film of the type that detects E. coliand indicates its presence by a change of color [EPMF] attached to aninner surface of a side of the soaker pad is illustrated. A roll ofcoextruded transparent, perforated, plastics material 900, including arolled length of web 902, is mounted on an unwind stand 904 and the endof the web is “threaded” around a series of drive and idler rollers,906, 908, 910, 912, and 914 such that when drive rollers 908 and 914 aredriven, the web 902 is pulled over the drive roller 908 so that theinside surface of the web 902 contacts the surface 922 of the water 918flowing through the trough 920. The trough 920 is connected to aconventional Langmuir-Blodgett water trough in such a manner as to causewater 918 to flow, from the Langmuir-Blodgett water trough,horizontally, underneath and parallel to web 902 and at a similar rateof flow to the speed of the forward movement of the web 902 ascontrolled by the rate of revolutions of drive roller 908. TheLangmuir-Blodgett water trough is provided to generate sufficientquantities of EPMF as required by the process. The EPMF floats on thesurface 922 of the water 918 and is carried with the flow of water at asimilar speed. When the web 902 contacts surface 922, the EPMF istransferred from the water surface to the web 902 and travels adjacentto a drying section 924 that evaporates any surplus water.

The web 902 is transferred from a vertical disposition across dryingsection 924 to horizontal by way of movement over the idler roller 910.Soaker (absorbent) pads 942 are positioned onto the surface of the web902 and a further perforated web 930 is unwound from roll 932 mounted onunwind stand 934. The two webs, with absorbent pads therebetween, aretransferred, between two drive rollers, 914 and into a heat sealingstation 936. The heat sealing station seals the two webs 902 and 930together by applying pressure through two sets of temperature controlledheat sealing bars 936 a, 936 b shown in FIG. 30. The pressure applied issufficient to distort the EPMF layer 960 and allow direct contact of theweb 902 and 930 surface layer material (SURLYN is a registered trademarkof Dupont), which is an ionomer resin and the SURLYN readily bondstogether. Webs 902 and 903 are composites which include an outer andinner layer, 962, 964, 966 and 968, respectively. The longitudinalslitting station 938 slits and separates the sealed soaker pads intocontinuous strips and the lateral cutting station 940 cuts across thewebs thereby separating the complete soaker pads.

Trays with Flaps, Trays with Channels

Trays with flaps and trays with channels which are constructed accordingto the present invention provide sturdier stackable trays which are ableto be evacuated of air and flushed with inert gasses and additionallyprovide channels and spaces to retain any liquids exuded from thepurchased goods.

Embodiment 1

Referring now to FIG. 31, a preferred packaging tray 3000 with flaps, isshown in a three dimensional drawing. The tray and flaps 3002 can bethermoformed from suitable materials such as polystyrene, polyester andpolypropylene in a solid or foamed sheet. The tray 3000 is mostpreferably thermoformed from an expanded polystyrene sheet of suitablethickness. Tray 3000 includes a base with perforations 3004. Fourupwardly extending sides terminate at a common flange 3006. Flaps 3002,3050, 3052 and 3054 are attached to flange 3006 at the external edge offlange by way of hinges at a hinge lines as shown. Flap 3002 is providedwith a profile that mirror images flap 3052, and flap 3050 is providedwith a profile that mirror images flap 3054. Flaps are attached to theouter edge of flange rim at hinges as shown, such that flaps 3002, 3050,3052 and 3054 will fold downwardly and intimately contact outer surfacesof the tray walls. The cross-sectional profile of flaps 3002, 3050,3052, 3054 are similar, flap 3002 and flap 3052 being of substantiallysimilar dimensions, and flap 3050 and flap 3054 being of substantiallysimilar dimensions. Flaps are formed with a rim 3008 that follows acontinuous path around the perimeter of the flaps. Flaps include aprofile which includes a flap base 3010, a flap flange wall 3012 andexternal flap vertical walls 3022. Buttresses 3016 are formed into flapprofile and connect flap flange wall 3012 to flap base 3010.Horizontally disposed ridges 3018 and 3020 provide horizontal channelsthat connect buttresses 3016 with continuous communication to openingsat each end of flaps in flap vertical walls 3022. Apertures 3014 areprovided between the ridges. Apertures 3014 thereby providecommunication through flaps at locations between the buttresses.Apertures 3026 are provided in upwardly extending walls of tray atpoints adjacent to buttresses such that when flaps are folded into avertically disposed position relative to tray, apertures 3026 providedirect communication through tray walls to buttress recesses 3024.

Referring now to FIG. 32, a three dimensional sketch of the tray 3000with flaps folded downwardly, is shown. Flaps are folded to a downwardlyposition, such that flap flange wall 3012 is in contact with theunderside of flange 3006. In this position, flaps are located in closeproximity and in contact with upwardly extending tray sides. Flap base3010 is substantially horizontally disposed relative to tray andprovides an extension to base of tray such that when tray with flapsfolded as shown in FIG. 32 is placed directly above a similar tray, flapbase is adjacent to and resting on flange 3006. It should be noted thatwhile packaging shown in FIG. 31 includes a tray with four flaps, anynumber of flaps from one to four may be provided according to preferenceand any specific requirements of a particular application.

Referring now to FIG. 33, tray base 3028 is shown with perforationstherein. Perforations 3004 may extend directly through tray base orpartially therethrough from either side. Perforations can provideabsorption of liquids that may accumulate adjacent thereto, by the opencell structure of the tray base material, such as when the tray has beenthermoformed from expanded polystyrene sheet which is, at least in part,of open cell structure. A space 3030 is shown which can be provided ifdesired. Space 3030 can be provided after tray with flaps is insertedinto a pre-formed shrink bag that is then exposed to elevatedtemperature that can cause the shrink bag to shrink around the tray withflaps. Alternatively, tray with flaps profile can be arranged such thatspace 3030 is substantially minimized when the tray base is in directand intimate contact with the shrink bag. Shrink bags may be printed asrequired with information of interest to any person interested inpurchasing the finished package. Such shrink bags are manufactured forexample by Robbie Manufacturing Inc., and are well known by the namePromoBag™. Shrink bags can be printed and fabricated from a clear,biaxially-oriented, heat shrinkable, anti-fog, polyolefin film materialmanufactured by E.I. Dupont De Nemours and known as Clysar AFG anti-fogshrink film. Clysar is a registered trade mark of Dupont, details ofwhich can be obtained from Dupont or on the internet at www.clysar.com.

Referring now to FIG. 34, a finished package is shown. The finishedpackage may contain perishable goods such as fresh red meats or freshground meats. Apertures 3032 can be provided at optimized locationsand/or as shown, in the outer cover shrink material 3034 of the finishedpackage 3036. Apertures 3032, which may be provided in the bag or web ofshrink material before or after package assembly, thereby providingdirect communication from external atmosphere through space 3038,apertures 3032, buttress recess 3024 and apertures 3036, and into thetray cavity 3040. A plurality of finished packages can be located insidea barrier master container as shown in FIG. 35 or any other mastercontainer/bag previously described above. Such barrier master containermay be thermoformed from a substantially gas barrier plastics material,such as a co-extruded multi-layer sheet of nylon//PVDC//polyethylene.After inserting finished packages into the barrier master container, themaster container can be located inside a vacuum chamber andsubstantially all atmospheric gases can thereby be evacuated from withinthe barrier master container, and within the finished packages. A gas orblend of suitable gases such as carbon dioxide, nitrogen, oxygen and anyother suitable gases, can be provided into the barrier master containerand the finished packages prior to hermetically sealing a substantiallygas barrier lid to flanges of the barrier master container. A pluralityof barrier master containers can then be positioned into a suitablysized shipping case as shown in FIG. 35, prior to shipping to anotherlocation.

Referring to FIGS. 116-117, in yet another preferred embodiment, themaster container 3226, with one or more finished packages, 3224,contained therein and including a “loaded master container”, may belocated inside a pressure vessel that is also arranged to operate as avacuum chamber with gas flushing. After location of the “loaded mastercontainer” inside a pressure vessel, the pressure vessel is closed andsealed from atmospheric air and substantially all air is evacuated to adesired and predetermined level. Following evacuation, the pressurevessel can be filled with a desired gas such as carbon dioxide to apredetermined, controlled and maintained pressure, above atmosphericpressure, such as 12 psi or up to 250 psi or higher, and held at apredetermined pressure for a period of time that will allow sufficientcarbon dioxide gas to dissolve in the perishable goods contained in thefinished packages in the master container. Carbon dioxide gas can beheld at the pressure, for a period of time, as required to prolong thesubsequent storage life of the perishable goods. Following the period oftime, the gas pressure may be lowered to a pressure equal to that of theprevailing atmospheric pressure and a gas barrier lid then hermeticallysealed to the flanges of the master container prior to opening thepressure vessel and removing the master container. The aforementionedprocess may include the steps of:

i) Locating a master container, 3226 with finished packages such asthose shown as 3224 contained therein, into a suitable pressure vessel.

ii) Closing and sealing the pressure vessel so as to isolate it fromatmospheric air.

iii) Evacuating substantially all air from within the pressure vessel.

iv) Providing a gas such as carbon dioxide in the pressure vessel at apressure above atmospheric pressure.

v) Holding the pressurized carbon dioxide provided in the pressurevessel for a period of time sufficient to enhance the keeping qualitiesof the perishable goods contained in the finished packages 3224, for anextended period.

vi) Lowering the gas pressure within the pressure vessel, to a levelequal to the prevailing atmospheric pressure.

vii) Hermetically heat sealing a gas barrier lid to the flanges of themaster container so as to substantially exclude oxygen gas from insidethe master container.

viii) Removing the master container from the pressure vesselautomatically.

ix) Locating another master container in the pressure vessel byautomatically and repeating steps i). to viii). in an automatic fashion.

x) Placing and sealing the master container into a finished shippingcase as shown in FIG. 36 which may be constructed of cardboard materialwith a crush test rating of 44 lbs. per inch.

xi) Shipping the finished container to another location.

xii) Removing the finished packages from the finished shipping case andallowing atmospheric air to penetrate through the apertures in thefinished package.

xiii) Repeating any or all of the above steps as required to maximizethe keeping qualities of the perishable goods.

Referring again to FIGS. 31 and 32, it can be seen that by manufacturingpackaging in this manner, any liquids that may accumulate within thetray cavity 3040, such as blood, will be substantially restricted fromescaping through apertures 3032 shown in FIG. 34. This restriction isprovided due to the arrangement of flaps and apertures therein, and thelocation of the apertures. Furthermore, perforations 3004 provide forretention of the liquids within the package.

Embodiment 2

An alternate embodiment of a tray with flaps constructed according tothe present invention is shown in FIGS. 37-124. The tray of FIG. 37includes four flaps as the tray of FIG. 31, with modifications asdescribed herein. FIG. 37 shows the cross-sectional detail of a tray.The tray walls are perforated in sections shown as incision section 3526and incision section 3528, shown in FIG. 39. Perforations may be in theform of small holes or incisions that extend fully through the traywalls, but may be only provided within the limits of regions shown asincision sections 3526 and 3528.

Referring now to FIG. 37, a cross-sectional view of finished package3514 is shown. Finished package 3514 includes a packaging tray 3556 withperishable goods located in tray cavity with an outer cover 3516. Theouter cover 3516 includes an envelope of material that completely coversand encloses the packaging tray and the perishable goods and is heatsealed to provide a sealed package. The outer cover 3516 may bemanufactured from a shrink material such as Clysar, manufactured byDuPont, and can be printed such that all surfaces are rendered opaqueleaving a transparent window 3522 on the upper surface only, as shown inFIG. 38 of the finished package. Clysar outer cover shrink material isthen heat shrunk such that the outer cover shrinks, holding the flapsagainst the tray walls. Apertures 3518 are provided on the four verticalfaces of the finished package when the base 3520 of tray is horizontallydisposed.

Referring now to FIG. 39, a detailed section of a packaging tray 3556with base 3520, tray wall 3524 and flange rim 3512 attached to flap 3508at a hinge 3532, is shown. The relative position of flap 3508 and thesection of tray is in the “open position”. Flap 3508 is attached athinge 3532 to flange rim 3512, however flap 3508 is not foldeddownwardly.

Referring now to the flap portion 3508 of FIG. 39, a cross-section isshown including a first and second raised peaks 3534 and 3536,respectively, and a flat area shown as face 3538 and face 3540; alsoshown are a ridge 3542; and gussets 3544, with connecting sectionstherebetween. Packaging tray includes a base 3520, flange rim 3512 withtray wall connecting base of tray to the flange rim. Tray wall includesrecess 3546, a first incision section 3526, recess 3548 and a secondincision section 3528. FIG. 40 shows a view of flap from the directionof arrow 3608. Flap 3508 includes a perimeter 3530 including hinge 3532,face 3538 and end flanges 3550 that are connected together to providethe continuous flat perimeter. Referring now to FIG. 126, depressions3552 may be provided in the flap section between peak 3534 and ridge3542 but do not perforate the section to provide direct communicationtherethrough. Apertures 3554 are also provided in face 3540.

Referring now to FIG. 41, an enlarged view of a tray portion of FIG. 124is shown. Flap and the tray wall are in intimate adjacent contact andridge 3542 and recess 3546 are engaged. Faces 3538 and 3540 as shown inFIG. 126, are in direct and intimate contact with the tray wall. Face3540 is located in recess 3548, thereby closing apertures 3554 when inthis position. Spaces 3560 and 3558 are directly adjacent to first andsecond incision sections 3526 and 3528. Shrink film 3516 holds flapfirmly and tightly against the tray wall providing sealed contentswithin the finished package. The package may be colorized to preventtranslucency. An adhesive such as a cold seal latex is provided betweenthe continuous perimeter 3530 of the flap as shown in FIG. 40. The traywall is inwardly flexible such that when a vacuum is provided within thetray cavity, the recess 3548 and face 3540 will separate to providedirect communication from within the tray cavity via perforations orincisions at first and second incision sections 3526 and 3528 throughapertures 3554, and through apertures 3518 in outer cover shrink film3516.

A plurality of finished packages 3514 of this embodiment can, as well,be stacked and placed inside a gas barrier master container inside avacuum chamber. Substantially all the air may be evacuated from withinthe gas barrier container and from inside the finished packages. Air isevacuated from within the packaging tray cavity through perforationsand/or incisions in the tray wall at first and second incisions 3526 and3528 into space 3560 and 3558, created when the flap is place adjacentthe tray wall, the air flows through apertures 3554 and apertures 3518.A suitable gas or gas blend such as nitrogen and carbon dioxide can thenbe provided into the vacuum chamber. The desired gas can be provided ina reverse flow direction into the finished packages by way of directcommunication through apertures 3518, apertures 3554 into spaces 3560and 3558, through perforations at incision sections 3526 and 3528 andthereby fill all free space within the finished packages and the gasbarrier master container. A gas barrier lid can then be hermeticallyheat sealed to the opening of the gas barrier master container and thefinished packages in the hermetically sealed master container can thenbe stored at a controlled temperature for a desired period of time priorto opening the master container and removal of the finished packages forretail sale.

In this way air and gasses can be removed from the finished and sealedpackages by evacuation and then replaced by gas flushing with a desiredgas, while liquids such as blood cannot readily escape.

Embodiment 3

Referring now to FIG. 271, another preferred packaging tray with flapsconstructed according to the present invention is shown in a threedimensional sketch. The packaging tray of this embodiment as with thepackaging trays of previous embodiments is similar in operation, butwith an alternate configuration of the channels through which evacuationand flushing is accomplished. The tray with flaps can be thermoformedfrom suitable plastics materials such as polystyrene, polyester andpolypropylene in a solid or foamed sheet. The present packaging tray ispreferably thermoformed from expanded polystyrene (EPS) sheet. The EPSsheet may include an “open cell” structure with a surfactant added priorto extrusion of the sheet such that the finished tray will have acapacity to absorb water and other liquids such as “purge” or blood. TheEPS sheet may be extruded with a “skin” on what will become the in-sideof the finished tray. The “skin” can be arranged so as not to absorb theliquids. The non absorbent “skin” may be provided on both surfaces ofthe extruded sheet.

The EPS sheet may be a multi-layer extruded sheet including threelayers. The three layers may include two outer layers of closed cell EPSfoam with an inner layer of open celled EPS foam. The outer layers maybe close celled and resistant to liquids such as blood and/or purge. Theinner layer of open celled EPS foam can be extruded with a suitablesurfactant contained therein that will enhance the liquid absorbingqualities of the open celled EPS foam.

The tray with flaps, shown in FIGS. 271-272, is most preferablythermoformed from expanded polystyrene sheet of suitable thickness, ofpreferably from about 0.01″ to about 0.15″, and most preferably about0.090″ and including at least two layers including a “skin” that willnot absorb the liquids and an adjacent layer of open cell structure thatwill absorb the liquids. FIG. 271 shows detail of the packaging traywith flaps extended and including a tray with tray cavity and four flapsshown as flap 7002, flap 7004, flap 7006, and flap 7008. Flap 7002 isprovided with a profile that mirror images flap 7006, and flap 7004 isprovided with a profile that mirror images flap 7008. Flaps 7002, 7004,7006 and 7008 are attached to the outer edge of flange rim 7010 athinges 7012 as shown, such that flaps 7002, 7004, 7006 and 7008 willfold downwardly and intimately contact outer surfaces of the tray walls.FIG. 272 shows the packaging tray with flaps folded downwardly. Thecross-sectional profile of flaps 7002, 7004, 7006 and 7008 are similar.Flap 7002 and flap 7006 being of substantially similar dimensions, andflap 7004 and flap 7008 being of substantially similar dimensions, butcan be longer or shorter than flaps 7002 and 7006. Referring yet againto FIG. 271, the packaging tray includes a base with four upwardlyextending tray walls terminating at a continuous flange rim 7010. Thetray walls can be perforated with openings directly therethrough withthe perforations arranged in sections shown as a first incision section7014 and a second incision section 7016. The perforations may be in theform of small holes or incisions that extend fully through the traywalls, but are preferably provided within the limits of regions shown asfirst and second incision sections 7014 and 7016, respectively.Apertures provided in sections 7014 and 7016 preferably extend intospaces between flaps and tray walls. Apertures 7020 provide a passagefor evacuating and flushing the tray in a master container, aspreviously described.

Embodiment 4

In another embodiment shown in FIGS. 45-49, a gap 4126 is providedbetween the flap at openings 4128 and the tray wall. The flap 4106 is ina folded down position and a gap 4126 is arranged between openings 4128and the tray side wall. Spaces 4130 and 4132 are directly adjacent toincision sections 4118 and 4116. The shrink film holds the flap firmlyand tightly against the tray wall. An adhesive such as a cold seallatex, or any other suitable adhesive may be provided between the flapsand the tray walls so as to cause sealing and bonding where contactbetween the flaps and the tray walls occurs. FIG. 46 provides details ofa cross-section through a section of the tray wall and the flap that arein direct contact. A “skin” 4134 is shown on the outer surfaces of thesection directly adjacent to EPS foam that is bonded together byadhesive layer 4146 causing a secure bonding and sealing of the traywall and the flap together. The sealing and bonding can be arranged soas to provide a completely sealed and “liquid tight” condition such thatany liquids contained in the spaces 4130 and 4132 will be retainedwithin the spaces. As shown in FIG. 49, an adhesive layer 4142 can beprovided between base 4138 and outer cover 4240 so as to bond the outercover 4240 to the base 4138.

Referring now to diagram FIG. 47, an elevation of finished package 4118,is shown. The finished package 4118 includes a packaging tray as shownin FIG. 45 with perishable goods located in tray cavity with an outercover 4120. The outer cover 4120 includes an envelope of material thatcompletely covers and encloses the packaging tray and the perishablegoods and is heat sealed to provide a sealed package. The outer cover4120 may be manufactured from a shrink material such as Clysar,manufactured by DuPont, or alternatively a stretch wrapping materialsuch as Mapac-M, a plasticized polyvinyl chloride web materialmanufactured by AEP Industries, Inc. The outer cover 4120 can be printedsuch that all surfaces are rendered opaque leaving a transparent window4122 on the upper surface as shown in FIG. 47. Clysar outer cover shrinkmaterial is then heat shrunk such that the outer cover shrinks, holdingflaps against the tray walls. Alternatively, if the Mapac-M, pPVCmaterial is used, heat shrinking may not be required and the Mapac-Mmaterial is stretched over the tray with flaps such that flaps contactthe tray walls. Apertures 4124 are preferably provided on the fourvertical faces of the finished package. The apertures are convenientlylocated in such a location so as to minimize the probability of anyliquids, such as blood or “purge”, escaping therethrough.

The EPS material, which may contain a suitable surfactant, used inproduction of the packaging tray may be manufactured so as to have acapacity to absorb liquids such as blood. Incisions and/or perforationsprovided in sections of the packaging tray can enhance the capacity ofthe EPS material to absorb the liquids such as blood.

Referring now to FIG. 48, an enlarged view of a cross section of thetray of FIG. 45 is shown. The flap and the tray wall are in intimatecontact and a gap 4126 is arranged between openings 4128 and the trayside wall. Spaces 4130 and 4132 are directly adjacent to incisionsections 4118 and 4116. A suitable adhesive can be applied between theflap and the tray at all direct points of contact therebetween causing asecure bonding and sealing of the tray wall and the flap together. Thesealing and bonding can be arranged so as to provide a substantiallysealed and “liquid tight” condition such that any liquids contained inspaces 4130 and 4132 will be retained. The shrink film, outer cover 4120holds the flap firmly and tightly against the tray wall. Referring nowto FIG. 49, a cross-section of the tray base portion and outer cover4120 are shown to be in adjacent disposition. An adhesive layer 4142 canbe provided so as to completely bond the outer cover 4120 to the base oftray 4138.

Furthermore, when the outside-surface of foam is arranged to have acapacity to absorb liquids, such liquids can be retained andsubstantially prevented from escaping from within the finished package.Additionally, a suitable adhesive can be provided between the trayflange rim 4144 and the outer cover 4120 where the continuous flange rim4144 is in contact with the outer cover 4120 so as to cause bonding in asubstantially liquid tight fashion therebetween. The openings atsections 4116 and 4118 in the tray wall, openings 4128 in the flaps andapertures 4124 in the outer cover 4120 provide a passage and directcommunication from the tray cavity to the outside of the finishedpackage such that when the finished package is exposed to a vacuum, airand gasses can be removed from within the package and replaced with adesired gas or mixture of gasses through the passage.

Embodiment 5

FIGS. 50-53 show yet another embodiment of a tray with flaps constructedaccording to the present invention. The tray 4808 of this embodiment issimilar in operation to the trays described above. Referring to FIG. 50,a tray is shown whereby flaps 4802 and 4806 can be arranged so as tohave no openings therein, and flaps 4800 and 4804 can be arranged tohave openings 4810 therein. Tray 4808 as shown in FIGS. 50-56 can beover wrapped with a web of pPVC to produce a finished package. The webof pPVC can be printed on the inner surface with a heat activatedcoating that can provide a method of bonding the web of pPVC to faces4812 on flaps 4802 and 4806 and face 4814 on flaps 4800 and 4804. Theheat activated coating can be applied to the web of pPVC by typicaloffset printing process and applied in those areas of pPVC that willcome into contact with the faces 4806 and 4814 after over wrapping thetray 4808 with the web of pPVC in such a manner that when heat isapplied to the pPVC in contact with the faces 4812 and 4814 the web ofpPVC will become bonded to the faces 4812 and 4814. The web of pPVC willthereby cover recess 4816 and recess 4818 in flaps 4800 and 4804 butwill not fully enclose and isolate the recesses leaving openings atopenings 4820. The web of pPVC can also thereby cover recess 4822 andrecess 4824 in flaps 4806 and 4802 but will not fully enclose andisolate the recesses leaving openings at openings 4826. In this way apath of direct communication from internal space of the tray to externalatmosphere is provided through apertures 4828 into space 4830 shown inFIG. 274 through apertures 4810 in flaps 4806 and 4802 only intorecessed 4822 and recesses 4824 and through openings 4826 into spacebetween the pPVC outer cover and tray through space 4830 and therefromthrough openings 4820 into recesses 4816 and 4818 and finally throughapertures that are provided in the outer cover pPVC adjacent to therecesses 4818 in flaps 4800 and 4804 to external atmosphere.

The tray 4808 may be thermoformed from any suitable material such asexpanded polystyrene EPS materials as shown in FIGS. 242-246 and FIGS.71-72. The EPS materials may include several layers of co-extrudedmaterial that are arranged so as to allow any liquids that may enterspace 4830 of FIG. 274 through apertures 4828 to be absorbed into theopen cell structure of EPS materials through surface perforations 4850that can be provided into the surface of the EPS materials that areadjacent to space 4830 only. Liquids can thereby be concealed within thelayers 4502 or 4508 as shown in FIG. 173.

The pPVC outer cover can be bonded to the underside of the tray 4808 byany suitable method, such as heat sealing or adhesive bonding, so as tofollow contours of recess 4832 shown in FIG. 173. The pPVC outer covercan also be bonded, by any suitable method, such as heat sealing oradhesive bonding, to flange rim 4834 along the full length and perimeterthereof so as to inhibit liquids from passing between the flange rim4834 and the pPVC over wrapping web of material after the bonding.

In this way liquids that may accumulate in internal space of tray arerestricted from escaping from within the finished package, whileproviding a path to allow extraction and injection of suitable gassesinto and out of the internal space of tray.

In another preferred embodiment the flaps may be extended as shown inFIG. 54, flap 5056 to provide additional cushioning around theperimeter. The additional cushioning can provide protection of thepackage and the package contents during shipping from the point ofproduction of the finished packages and a point of sale to consumerssuch as a supermarket. FIG. 273 shows a tray flap with a space whereinsubstances 4850 may be added, such as wax-coated iron particles. FIG.274 shows a cross section of a tray with flaps, wherein the flaps form aplurality of spaces between the tray wall and the flap (outer wall).

Embodiment 6

Referring now to FIG. 55, yet another preferred packaging tray 5200 withflaps, is shown. The flaps are shown folded into a desired position andbonded to the tray base and/or walls. The packaging tray with flaps canbe thermoformed from suitable plastic materials such as polystyrene,polyester and polypropylene in a solid or foamed sheet. The presentpackaging tray is preferably thermoformed from expanded polystyrene(EPS) sheet. The EPS sheet may include a single or multi-layerconstruction as shown in FIG. 59. Any suitable sheet of EPS material maybe used but most preferably the sheet includes 3 layers 5204, 5206, and5208. The layer 5204 preferably includes a layer of solid plasticmaterial such as polystyrene sheet with any suitable thickness,preferably about 0.001″ and is laminated to layer 5206. Layers 5206 and5208 preferably include “closed” or “open cell” structures either withor without a surfactant added prior to extrusion of the sheet such thatthe finished tray may have a capacity to absorb water and other liquidssuch as “purge” or blood. The EPS sheet may be extruded with a “skin”covering on a surface that will become the in-side of the finished tray.The “skin” can be arranged so as not to absorb the liquids. Thenon-absorbent “skin” may be provided on both surfaces of the extrudedsheet. The layer 5204 may contain a white or other suitable pigment,such as white titanium dioxide in such a quantity so as to preventvisibility of any discoloration that may be caused by blood or purgeabsorbed by layers 5206 or 5208. In this way the layer 5204, which willbe visible, will not show substantial discoloration as a result of bloodor purge that has been absorbed by any of the other layers.

Tray 5200 with flaps is most preferably thermoformed from sheet materialof suitable thickness, preferably about 0.01″ to about 0.15″ butpreferably about 0.090″ and includes a tray with tray cavity and fourflaps. Two flaps are shown as flap 5210 and flap 5212. Flap 5210 is anend flap and flap 5212 is a side flap. The construction of tray 5200with folded and bonded flaps, allows for production of suitably rigidfinished trays even though the thickness of the sheet material fromwhich the tray is formed, is substantially thinner than would otherwisebe required in conventionally formed packaging trays that do not have“flaps”.

Flap 5210 can be provided with a profile that is a mirror image of 5214(not shown), and flap 5212 can be provided with a profile that is amirror image of flap 5216. Flaps 5210, 5212, 5214 and 5216 are attachedto the outer edge of flange 5218 at hinges as shown by the hinge lines,such that flaps 5210, 5212, 5214 and 5216 can be folded downwardly andintimately contact outer surfaces of the tray walls at locations asrequired. One or more flaps may be provided and folded to provide anenclosed space 5222 and/or cavity 5220 shown in FIG. 58. Thecross-sectional profile of flaps 5210 and 5214 are similar. Thecross-sectional profile of flaps 5212, and 5216 can be similar.

Referring again to FIG. 55, the packaging tray includes a base with fourupwardly extending tray walls terminating at a continuous flange 5218.Tray walls can be perforated with openings 5224 directly therethroughwith the perforations arranged so as to communicate between the traycavity and space 5222. The apertures 5224 can be located so as to allowany purge that may be present in the tray cavity 5226 to passtherethrough and into space 5222. The perforations 5224, may includesmall holes, slots or incisions that extend fully through the traywalls. The flaps can be bonded to the tray walls so as to retain anyliquids that enter therebetween and into space 5222. Any suitable liquidabsorbing medium may be attached to one or more of the flaps so thatwhen the flaps are folded and bonded the liquid absorbing material willbe enclosed within space 5222. The liquid absorbing material couldtherefore absorb any liquids that may enter the space 5222 during use ofthe tray.

Referring again to FIG. 55, recesses 5228 and 5230 are shown in flap5212. Slots 5232 are shown in flap 5212 and are located in recess 5228.Perforations 5234 are provided in flap 5212 and are located in recess5228. Recesses 5238 and 5240 are shown in flap 5210. A suitable adhesiveis provided at the interface between flaps and tray walls so as toprovide a bonding of flaps to tray walls. Bonding of flaps and traywalls is provided in such a manner so as to ensure complete bonding offlaps to the tray wall along strips that follow a path close to whatwill become a perimeter of the flaps. FIG. 58 shows a cross-sectionthrough flap 5212 and tray wall showing enclosed space 5222. Space 5222is enclosed between the flap and the tray wall in a substantially liquidtight manner. Iron powder deposits 5244 can be applied to locations onthe tray walls and flaps adjacent to space 5222 and also to theunderside surface of the tray base. The iron powder deposits 5244 mayinclude iron powder particles that have been fully coated with a specialcoating material, such as wax. The coating can be arranged to preventdirect contact of the iron particles with ambient air or any gas thatmay be present, until such direct contact with the air or gas isrequired. The coating may have physical and/or chemical properties thatcan be activated by exposure to microwaves, radio waves or a magneticfield. For example, when using wax as a coating, microwaves will causethe iron particles to heat up, thereby melting the wax and exposing theiron particles. The coating may also contain an adhesive that is heatactivated and otherwise does not bond with other matter until activatedand/or heated by exposure to any suitable microwaves, radio waves,magnetic field or any suitable electrically or sonically induced wavesor field. The coated iron particles 5244 can be deposited on thesurfaces by apparatus shown in FIG. 140 herein. The coated particles canbe coated with a substantially gas barrier substance that is alteredwhen exposed to suitable microwaves or an electrically induced magneticfield. Exposure to the waves, field or microwave can cause the coatinggas barrier substance to physically or chemically alter and become gaspermeable, in such a manner that will cause the iron particles toimmediately or subsequently react with any gases such as oxygen that maybe present. The quantity of iron particles 5244 provided and attached tothe tray and flap selected surfaces can be measured and controlled in anamount having an equal or greater capacity that may be required toabsorb substantially all oxygen gas that may be present and/or becomepresent by permeating into the finished package.

Referring now to FIGS. 55-209, a plurality of finished packages that maybe conveniently stacked as shown in FIG. 62 may be placed in a gasbarrier master container which can then be evacuated of substantiallyall air. Ambient air that may be present within the finished packagetray cavities and spaces such as 5222 shown in FIG. 58 will be evacuatedthrough apertures 5306 and replaced with a suitable gas. The air can bereplaced or displaced with any suitable gas prior to hermeticallysealing the master container to provide a single container with finishedpackages enclosed and sealed therein. At a convenient time after sealingthe sealed master containers may be exposed to a suitable level ofmicrowaves or magnetic field or other suitable source of energy thatwill selectively alter the gas barrier coating on the iron particles soas to render it permeable and further activate iron particles to oxidizewith any residual oxygen that may remain within the master container.The substance “IPD” 5244 may include any suitable substance that can beapplied in any convenient manner to the trays 5200 so as to remaininactivated until exposed to the microwave and/or magnetic field in sucha manner as to render the IPD activated. When the IPD is selectivelyactivated by any suitable source of energy that is applied before orafter the trays are loaded with goods, the IPD can react with andthereby absorb any residual oxygen gas remaining within the finishedpackages, in such a manner so as to inhibit the formation ofmetmyoglobin that may otherwise be formed as a result of availableoxygen that has been released during reduction of any oxymyoglobin thatmay be present in the finished package after sealing the mastercontainer.

The IPD can be applied in any suitable manner to selected surfaces ofthe tray and/or flaps so as to not directly contact but to be in closeproximity to goods that is subsequently loaded into the cavities oftrays. Ground or sliced red meats may have been exposed to ambientoxygen, after grinding or slicing and prior to packaging, for such aperiod of time that deoxymyoglobin present in freshly cut red meats hasreacted with ambient atmospheric oxygen to form oxymyoglobin. Fresh meatwith oxymyoglobin may be then packaged in a substantially oxygen freegas package such as a barrier master container that has been evacuatedand filled with any suitable gas that may contain less than 500 PPMoxygen. After packaging, the oxymyoglobin will reduce to deoxymyoglobinthereby releasing oxygen gas into the spaces in the master container.The released oxygen can then react with the deoxymyoglobin to formmetmyoglobin. The metmyoglobin is brown in color and is undesirable andconsumers are unlikely to purchase meat that is brown in color. The IPDsubstance can be provided within the finished packages in such a mannerso as to substantially absorb, and thereby render inactive, the oxygenthat has been released by reduction of the oxymyoglobin todeoxymyoglobin, after hermetically sealing the finished packages. Inthis way the formation of undesirable metmyoglobin can be inhibitedand/or minimized. In order to enhance the absorption of oxygen gas bythe substance IPD, any suitable method to cause circulation and movementof any gas inside the finished package can be incorporated. Such methodsmay include shaking or suitable movement of the finished and sealedmaster containers in such a manner so as to cause gas to circulatethrough apertures 5306 from the spaces in the tray cavities and moreparticularly near and over the exposed surfaces of the goods.

In another alternate embodiment, the present invention provides capsulesof suitable size but most preferably having a diameter orwidest/longest/deepest dimension of less than 0.25″, wherein capsuleshave a generally rounded, spherical or oval profile with a continuouscapsule wall of any suitable thickness but most preferably approximately00.060″ thickness, with a cavity enclosed within the continuous capsulewall and wherein each enclosed capsule cavity contains a suitablequantity of any selected agent, substance or material, such as, forexample, a bactericide, a water absorbing gel, a CO₂ generating agent.The capsule wall may be manufactured from a material such as wax or aflexible waxy plastics material that is affected by micro waves, RF(radio frequency) or a magnetic field that is generated from acontrolled source and with such an intensity that it can cause thecapsule walls to rupture or soften or dissolve and to such an extentthat the contents of the capsule cavities will be expelled or allowed toescape from within the enclosed capsule cavity. A suitable quantity ofcapsules or combination of capsules containing separate quantities ofseveral agents, with any selected agent(s) contained therein may beenclosed, for example, within the cavity(ies) of any suitable packagingtray prior to use in a packaging application. At any time during orafter assembly of such a tray with capsules contained therein, it may beexposed to the appropriate source and intensity of micro waves, RF(radio frequency) and/or a magnetic field and in such a way so as tocause the release of any agents contained within the cavity of thecapsules. In this way, for example, a bactericide may be held untilrequired for use within the package walls or base and after assembly ofthe package such as a tray containing fresh red meat, at which time thebactericide can be released and thereby made available to substantiallykill bacteria, fungi, virus or any undesirable life form that may bedangerous to human or animal life.

Referring now to FIG. 64, a finished package 5300 is shown with a seal5324, that extends continuously around a horizontally disposed perimeterof the finished package. Seal 5324 is provided so as to bond an overwrap 5326, which is positioned above the seal 5324, to an over wrap 5328which is located below the seal 5324. The seal 5324 can be provided byany suitable method such as by heating and is arranged to be a completeand continuous and gas tight seal along the full length of the seal5324. The over wraps 5326 and 5328 may be either both clear andtransparent or alternatively printed but most preferably the 5328 willbe printed as desired. 5326 and 5328 may be produced from asubstantially gas barrier material such that when sealed along seal 5324a hermetically sealed finished package is produced. Alternatively gaspermeable plastic materials may be used to produce the over wraps. Theprofile of over wrap 5326 and 5328 may be provided by a thermoformingmethod prior to assembly of the finished package whereby a loaded tray5300 is located into a thermoformed over wrap 5328 prior to sealing athermoformed over wrap 5326 thereto at seal 5324. Alternatively, bothover wraps 5326 and 5328 may be produced from a web of “stretched”material such as pPVC. The web of pPVC may be held taught above adepression where the depression is similar in profile to the lowersection of tray 5300 but slightly larger so as to allow a neat locationof tray 5300 therein. A vacuum can be applied in the depression so as tostretch the pPVC web therein and thereby provide a lower over wrap 5328.Tray 5300 can be located into the stretched pPVC depression and heatsealed at 5324 to an over wrap 5326 that can be formed in a similarmanner by stretching into an inverted depression, of suitable size, thatis located directly above and aligned therewith so as to allow suchsealing at seal 5324. Apertures 5306 may be provided in the over wrap5328 or alternatively, over wrap 5328 may be maintained withoutapertures so as to provide a complete finished and substantially gasbarrier package.

In another preferred embodiment, iron powder that has been completelycoated with a substance, such as a special type of wax, can be includedin one or more layers of a tray thermoformed from a one, two, three ormore layer sheet of co-extruded EPS foam. The special type of waxcoating can be arranged so as to prevent contact of undesirablesubstances such as water, with the powdered iron that is completelycovered by the special type of wax coating, until a suitable time. Thespecial type of wax coating can be arranged so as to melt or otherwisechange when exposed to an electromagnetic field, microwaves or othersuitable medium. The melting or change to the special type of waxcoating can allow the powdered iron to become exposed and thereby reactwith oxygen gas that may be present, after exposure to theelectromagnetic field, microwave or suitable medium. In this way trays,formed from the EPS foam with coated iron powder contained therein, canbe used to package perishable goods and when the tray with perishablegoods has been over wrapped with a gas permeable web of plasticsmaterials, can be located in a master container with a suitable gas, andall hermetically sealed so that the master container contains the overwrapped tray with perishable goods and a suitable gas. Immediately afterhermetically sealing the master container, the master container can beexposed to an electromagnetic field, microwave or other suitable medium,so as to change the coating and thereby expose the iron powder and allowreaction of the iron powder with any oxygen gas that may be generatedwithin the master container as a result of reduction of oxymyoglobin.

Immediately prior to or after loading goods such as ground or slicedmeats into the tray cavities, the trays 5320 can be exposed to asuitable level of microwaves or a magnetic field sufficient to causecoating SCM to be altered and thereby allowing the IPD to react with anyoxygen that is present and in contact with the IPD. In this way and dueto the close proximity of the IPD to the oxymyoglobin, the oxygen thatis released by reduction of the oxymyoglobin, can be quickly absorbed bythe iron powder IPD as soon as it contacts therewith.

Pre-conditioning of the goods, prior to loading into the trays canreduce the quantity of oxymyoglobin formed immediately after slicing orgrinding of the goods but before packaging and sealing in the mastercontainer. The pre-conditioning can include the process of exposing thegoods to carbon dioxide or any suitable gas at any suitable pressure orhigh pressure immediately after and/or during slicing and/or grinding.The goods can be exposed to the gas at high pressure in such a mannerthat the gas becomes highly soluble in liquids and oils present in thegoods, and dissolves in the liquids and oils. The goods can be exposedto high pressure gas for an adequate period of time to allow saturationof the liquids with soluble gas. Saturation of liquids and oils willtherefore occur at the high pressure. Therefore, when goods are removedfrom exposure to high pressure gas and returned to exposure to normalambient atmosphere for subsequent packaging into finished package and/ormaster container, gas (or gases) that have dissolved in the liquids andoils will be then exposed to a lower gas pressure. Gas that hasdissolved under the high pressure into liquids will be “released” andreturn to a gaseous condition. The release of gas will occur at thesurface of goods and during this event, any oxygen that is present inatmospheric air will be inhibited from contacting the surface of thegoods. This procedure can therefore provide a method to slice andpackage goods while reducing and minimizing the formation ofoxymyoglobin immediately prior to packaging and consequently minimizingthe otherwise corresponding formation of metmyoglobin after packaging inthe manner described herein. The pre-conditioning process can alsoinclude the method of lowering the temperature of the goods to anysuitable “pre-conditioning” temperature that may be 28 degrees F. priorto slicing and/or subsequent immersion in high pressure gas withexposure thereto. After removal of the goods from immersion in andexposure to high pressure gas at a lower temperature the goods will beexposed to ambient atmospheric conditions which will be at a highertemperature and lower gas pressure. After packaging the goods in thefinished package and/or master container, the packaged goods can bestored and maintained within a suitable temperature range that may behigher than the “pre-conditioning” temperature. The pre-conditioningtemperature may be maintained within a range of approximately 29 to 32degrees F. The suitable post conditioning temperature range may bemaintained between 33 to 36 degrees F. The difference between thepre-conditioning temperature and the post conditioning temperature maybe less than 15 degrees F. Goods may be pre-conditioned by passingthrough a first tube at a suitable pressure where the first tube has adiameter of ‘X’ and is centrally located within a second tube that has adiameter of ‘X’+1 inch or more and thereby providing a space between theouter surface of the first tube and the inner surface of the secondtube. A temperature controlled liquid such as brine or glycol can beprovided in the space between the first and second tubes and therebyprovide a cooling or heating devices that will allow temperaturecontrolling of goods that are present in the first tube. A specified andcontrolled quantity of any suitable gas at any suitable temperature andpressure can also be provided in the first tube with goods so as toprovide a controlled devices of dissolving suitable gasses into thegoods. The goods with the gas can be held in the first tube for asuitable period of time so as to allow the gas to dissolve into theliquids and oils in the goods at a suitable temperature. The first tubecan be filled with compacted goods in such a manner so as to restrictany gas, that is provided therein, from escaping or leaking there from.The first tube may be provided with mixer therein to allow mixing ofgoods contained therein. The first tube may be fitted with scraper andsubstantially remove any solids, such as frozen liquids, ice and/orsolids that may accumulate on the internal surfaces thereof.

Referring now to FIG. 56, a cross-sectional view through tray wall andflap 5212 is shown. For illustration purposes, a section of web material5246 is shown bonded to plane 5248. Recesses 5236, and 5230 aretherefore shown as enclosed channels. Cavity 5220 is fully enclosed andsealed from external communication save through perforations 5234 bybonding at interface 5242. Gases can therefore communicate through theperforations 5234 and into the cavity 5220 and recess 5236. The gasescan therefore come into direct contact with deposits 5244. The deposits5244 are preferably applied to tray and flap surfaces that will not comeinto contact with any goods that are subsequently located in the traycavity.

Referring again to FIGS. 57-58, a cross-sectional view through crest5250 is detailed in FIG. 57 with hinge 5252 between the flap 5210 andflange 5218. In FIG. 58, tray 5200 is shown in a horizontal dispositionwith the opening in tray cavity facing upwardly. The tray base isprofiled so as to be higher at the center of the tray base than at thelowest point of the tray cavity (at a radius connecting the tray base tothe upwardly extending tray wall) and a clearance, designated by arrow5254 is shown. The clearance 5254 is the distance (clearance) measuredfrom the lowest point of the tray 5200, at the side flaps and thehighest point of the under surface of the tray base. The clearance 5254is arranged so as to suitably accommodate and “mate” with the crest 5250when another tray (not shown) is located above and placed onto a lowertray 5200. In another alternate, the clearance 5254 may be enclosed byover wrap material to provide a cavity into which purge may enterthrough suitably located apertures in the tray. Suitable liquidabsorbing material with a suitable capacity may be provided between theover wrap and underside of the tray base. The crest 5260 and clearance5254 prevent the base of a stacked tray from contact with an overwrap onthe bottom tray. In this manner, the goods are prevented from touchingthe base of an adjacent tray.

Embodiment 7

Referring now to FIGS. 60-61, another preferred embodiment of a tray5300 with flaps is shown. Tray 5300 has similar features to tray 5200;therefore, those features ill be alluded to by the same referencenumerals. Tray 5300 with depression therein is shown after over wrappingwith overwrap web 5302. Web 5302 may include a plastic web of materialsuch as pPVC. The depression may be substantially filled with goods suchas ground beef prior to over wrapping with the over wrap 5302. Over wrap5302 may be stretched in such a manner as to contact the goods in thedepression. The web of material 5302 may be printed with informationthat gives detail of the contents of the over wrapped tray. Further morethe inner surface of the over wrap 5302 may have been processed and aheat activated coating applied thereto, by any suitable method, and inthose areas that will come into contact with planes 5258 and 5256 asshown in FIG. 55. A suitable heat source can be provided to activate theheat activated coating so as to cause bonding of the web 5302 to flaps5212 and 5210 at planes 5256 and 5258 and at locations shown as shadedsections 5304. Alternatively, the areas shown as 5258 and 5256 may becoated, by any suitable method, such as by “ink-jet”, with any suitablebonding material such as a heat activated coating. Apertures 5306 may beprovided as shown. Apertures 5306 can be provided after bonding of theweb to plane 5256 such that communication directly into recess 5238 isprovided. A cross-sectional view is shown in FIG. 61 through where web5302 has been bonded to plane 5256 thereby providing space 5308 andrecess 5310. Apertures 5312 in flap, apertures 5314 in wall of tray andapertures 5306 in web 5302 are provided. In this way a communication isprovided between the tray cavity to the outside of the over wrapped trayfollowing a path that will readily allow gases to communicatetherethrough but will restrict escape of liquids such as purge. Thecommunication follows a path through aperture 5314 into space 5316,through aperture 5312 into recess 5310, through recess 5310 to space5308, through space 5308 to recess 5318, through recess 5318 to recess5238 and through aperture 5306.

Referring now to FIG. 62, a stack of 4 finished packages of the trayshown in FIG. 60 is shown. A cross-sectional view is shown in FIG. 63,through the stack of packages. It can be seen that with this arrangementan upper tray is in contact and rests on the flange of a lower tray. Ascan also be seen, clearance provided in the underside of the base oftray mates with the upper profile of a lower tray whereby the contentsof a lower tray are located in close proximity to the upper tray but arenot in contact with the underside of the upper tray.

Embodiment 8

Referring now to FIG. 65, a preferred packaging tray 3200 with flaps, isshown. FIG. 65 shows a flap 3202 attached to a tray 3200 by a hinge 3204to flange 3206. Tray can also be provided with similar flaps attached byhinges to all four sides of the tray at hinge lines between flaps andflanges. However, FIG. 65 shows a tray that has two flaps, on opposingsides, where one only flap can be seen.

Packaging tray 3200 includes a substantially flat base that may havedepressions, ridges, apertures and/or penetrations provided therein,with upwardly extending walls terminating at a continuous flange 3206. Aledge 3208 is provided in two of the four walls in a horizontallydisposed position and level, across the face of the side wall andbetween the flange and the base of tray. The other two walls have flaps3202 attached thereto, at a hinge connecting the flaps to the flange.Apertures 3210 provided are provided in ledge 3208. Tray 3200 with flaps3202 may be thermoformed from a suitable material such as solid orfoamed polystyrene (EPS), polyester, polypropylene or other suitablematerial. Apertures 3212 are provided in flaps at optimized locationsthat will restrict passage of solid or liquid matter therethrough. Analternative aperture construction is also shown as slot 3234 cut througha compressed section 3240 of tray in cross-section FIG. 68 and in anenlarged view, FIG. 69, showing details of the slot 3234 provided in asection of the flap along ridge 3214. Slots may also be located at otherlocations. The region surrounding the slot is compressed to provide asection of thinner cross-sectional thickness. Slot 3234 includes anincision in the compressed section of the ridge and may be provided withan “H” profile. The slot with “H” profile provides two adjacent flaps,3236 and 3238, respectively, that can open when a differential in gaspressure is provided on opposite sides of the flap, however, when thegas pressure differential has equalized the two adjacent flaps shown as“H” flaps, can close to the former condition before opening.

Flaps 3202 are folded downwardly, against the upwardly extendingadjacent tray walls 3216 as shown in end view of flap in FIG. 66, priorto over wrapping. Flaps 3202 can be provided with a fastening lug 3242that is profiled so as to “mate” with a corresponding fastening recess3244 provided in tray 3200. The fastening lug 3242 and fastening recess3244 holds flap 3202 in a downwardly located position in convenientreadiness to be inserted into a bag prior to sealing and shrinking.Flaps 3202 may otherwise prevent automated loading of the tray withperishable goods therein, into the bag.

Perishable goods such as fresh ground beef can be placed in the traycavity prior to tray and perishable goods being over wrapped and shrinkwrapped with a material such as Clysar AFG Anti Fog Polyolefin ShrinkFilm. Shrink film may be in the form of a preformed fabricated printedpouch (or bag) or alternatively, unrolled from a continuous web ofrolled material that is formed into a tube on a machine such as a flowoverwrapper, and cut into convenient sized sections that can be heatsealed (or cold sealed), so as to completely cover the assembledpackaging tray and contents, prior to heat shrinking. The assembled traywith flaps, perishable goods and sealed overwrap are then passed througha heat shrink tunnel that causes the overwrap material to shrink andprovide a taut and relatively tight cover over the packaging tray andgoods. Flap 3202 is provided with a continuous rim 3246. The continuousrim 3246 is provided in such a manner so as to contact the inner surfaceof the outer cover 3218. Rim is in continuous contact around theperimeter of the flap and substantially restricts passage of matterbetween the rim and the outer cover 3218 as shown in FIG. 112.

Referring now to FIG. 112, a cross-section through the tray with flapsis shown after outer cover 3218 has been heat shrunk into a finishedposition. Apertures 3220 are provided in the outer cover. A space 3222is provided between the flap and the outer cover such that apertures3220 provide direct communication between the space 3222 and externalatmosphere. A finished package 3224 is shown in FIG. 113. A plurality offinished packages can be assembled in a group that may include a totalof twelve finished packages in three adjacent stacks of four finishedpackages. The group of twelve packages can be transferred byautomatically into a thermoformed, substantially gas barrier, outermaster container as shown in FIGS. 35-36. The barrier master container3226 containing the finished packages may be located within a vacuumchamber and substantially all air evacuated from the vacuum chamber andfrom within the finished packages and the barrier master container. Inthis way, substantially all atmospheric air can be removed from withinthe finished packages via a route that follows a path through apertures3210 (FIG. 65) into space 3228 (FIG. 66), through apertures 3212 (FIG.65) into space 3222 (FIG. 112) and through apertures 3220 (FIG. 112).The vacuum chamber may then be filled with a desired gas such as anysingle, oxygen free or oxygen enriched blend of gases includingnitrogen, carbon dioxide and/or any other suitable gases. The gases willtherefore substantially fill all voids and spaces within the barriermaster container and the finished packages contained therein, byfollowing the reverse route of the path along which atmospheric gaseshad previously been evacuated. In this way, finished package 3224provides a suitable package with space therein that can be filled withdesired gases as required, while restricting the escape of liquid orsolid matter, from within the finished package, to external atmosphere.

Referring again to FIG. 112 and FIG. 113, it can be understood that whena plurality of finished packages are assembled in a stack, the base oftray 3230 with adjacent flaps will be in intimate contact with the uppersurface of the finished packages. The flaps will be in adjacent contactwith the flange regions of the lower package, thereby supporting theweight of packages stacked above. Therefore, the perishable goodscontained in any package located beneath a package stacked above, willbe protected from damage.

Embodiment 9

Referring now to FIG. 88 an isometric projection of a finished package2500 constructed according to the present invention is shown and across-section through an empty package 2500 is shown in FIG. 116. Tray2502 is thermoformed from a suitable material such as expandedpolystyrene. Flaps 2504 are connected to the tray by way of hinges 2506.Flaps can rotate about the hinges such that upper surface of flanges2508 can contact directly and in alignment with flanges 2510 of theflaps.

Referring now to FIG. 115, a perishable goods 2600 such as ground meatis located in tray 2502 and a web 2512 is positioned directly above andover the tray and perishable goods. Web 2512 includes a transparentsheet of a suitable material such as plasticized PVC that has beencoated with a heat activated adhesive covering the areas of the web thatwill come into contact with flange 2508 thereby providing a method ofsealing web 2512 to the flanges 2508. After the web has been heat sealedto the flanges 2508, it is severed along the perimeter of flanges 2508.The web is hermetically sealed around the full flange extending aroundthe perimeter of the tray. Flaps 2514 and 2504 can then be rotated abouthinges 2506 and flanges 2510 of flaps are sealed to flanges 2508 of thetray as shown in FIG. 114.

Referring again to FIG. 115, flanges 2516 and 2518 are convenientlyformed into a portion of the end walls of the tray. Web 2512 can besealed to the flanges 2516 and 2518 as shown. Aperture 2520 can beprovided in the location shown such that direct communication betweenthe gas contained between the tray and the web 2512 and externalatmosphere is enabled. The location of aperture 2520 inhibits the egressof any liquids that may accumulate within the package from escapingtherethrough. Additionally or alternatively, aperture 2522 is alsoshown. A plurality of finished packages can be stacked together suchthat face 2524 engages with face 2526. Such engagement of faces providesa secure method of stacking finished packages.

Embodiment 10

Referring now to FIG. 117, another preferred embodiment of a finishedpackage constructed in accordance with the present invention is shown.The package 2544 includes a tray 2526 and a tray cover 2528. Tray andcover can be formed from suitable materials such as expanded polystyrene(EPS). Cover 2528 has a window 2530 cut therein as shown and web 2532 isstretched taut and heat sealed to flanges 2534. Tray 2526 and tray cover2528 are hermetically sealed together at flanges 2536 and 2538. Walls oftray and the cover can be printed directly thereon with informationdescribing the contents of the package with all legally requiredinformation, pricing, weight of contents and cost per unit weight.Recesses 2540 (four) in ridge 2542 are conveniently provided to allowfor evacuation of air from between stacked packages. Recesses 2540 canalso provide for location of bands of printed paper that may providefurther information and details of package contents.

Referring now to FIG. 118, a cross-section through the end section oftwo stacked and finished packages 2544 of FIG. 117 is shown. Theperishable goods contents of the packages have been omitted for clarity.Faces 2546 and 2548 engage between the stacked finished packages.Engagement of the faces causes the outward urging of ridge 2550 of thelower package. The weight of the upper package is thereby transferredthrough the walls of the lower tray cover while inhibiting the inwarddisplacement of flange 2552. Such an arrangement minimizes thelikelihood of undesirable pressure being applied to the perishable goodscontents of the lower tray by depressing the flange 2552 downwardly.

FIGS. 119-121 show an enlarged section of flange 2552, including sideelevation, FIG. 120, and a plan view FIG. 119, of the underside of FIG.120, and a further end view, FIG. 121, is shown with grooves and slotsthat allow direct communication between the inside of the finishedpackage and atmospheric gases on the outside. Web 2554 is heat sealedalong a continuous seal path 2556 and intermittent seals 2562 are shownwith slots 2558 therebetween. Slot 2560 is therefore in directcommunication with slots 2558 and 2564 and grooves 2566. Apertures 2568are located adjacent to slot 2560 and directly between continuous seal2556 and intermittent seals 2562. Web 2554 can include a sheet ofplasticized PVC and is tensioned prior to sealing as shown therebyproviding a transparent cover across the window. In this way directcommunication from within the package to atmosphere is provided throughapertures 2568, slot 2560, slots 2558, slot 2564, and grooves 2566,while minimizing the possibility of any accumulated liquids escapingthat may be present within the package.

Referring now to FIG. 122, three empty packages 9608 with web sealedthereto, are shown stacked together. A section through a finishedpackage 9610 is shown in FIG. 124, and a section through an individualpackage is shown in FIG. 123.

Referring now to FIG. 125 three finished packages 2570 are stackedtogether within a flexible gas barrier container 2572. A gas barrier lid2574 is hermetically heat sealed to gas barrier container 2572 aftersubstantially all air has been evacuated and replaced with a suitablegas that may be substantially oxygen free.

Embodiment 11

Referring now to FIG. 126, another alternative embodiment of a tray withflaps constructed according to the present invention is shown. Tray 2578includes a first 2576 and second flap (not shown). Flap 2576 is attachedto tray 2578 by hinge 2580. Ridges 2582 are formed in flap andcorresponding ridges 2584 are formed in tray such that when flanges offlap and tray are in contact, portions of ridges are also in contact.Web 2586 is heat sealed to flanges 2588 and 2590. Apertures 2592 and2594 are provided in the web such that when flanges of the flap and trayare parallel to each other and in closest proximity, apertures are inalignment providing direct communication therethrough. Concentricdepressions 2596 are shown in FIG. 126 and in the detail ofcross-section FIG. 127. Tray 2578 may be formed from a three layerconstruction of expanded polystyrene where the inner layer includes an“open” cell structure that will absorb liquids such as water and blood.Depressions are provided on the inner surface of the tray, to allowcontact of liquids, that may be present in the tray, with the innercells of the tray and allowing absorption of liquids by the open cellstructure.

Embodiment 12

Referring now to FIGS. 128-130, another preferred embodiment of a traywith flaps constructed according to the present invention is shown. FIG.130 shows a cross-section through a tray 2400, FIG. 129 shows across-section through a tray 2402 that contains ground meat with a web2404 stretched over the ground meat and sealed to flanges 2406, 2408 andedge portion 2410. FIG. 128 shows a cross-section through a portion of amaster container 2412 with finished packages 2414 stacked therein. Aflap 2415 is shown that has been severed from tray 2402 and web 2404 isalso sealed to flap 2416. A space 2418 is provided between web 2404 andinner surface of the flap 2416 providing direct communication betweenrecess 2420 and aperture 2422. Flap 2416 and tray 2402 are thereforeattached together by web 2404 and a gap 2424 is provided between flap2416 and the tray 2402. An aperture 2422 is provided in web 2404 at flap2416 portion and an aperture 2426 is also provided in web 2404 at trayportion. Recesses 2420 are provided in the flap 2416 such that when web2404 is sealed thereto recess 2420 provides direct communicationtherethrough from atmosphere to the space between the flap 2416 and web2404. Recesses 2420 are conveniently located in wall of flap 2416between flange 2406 and horizontal edge portion 2410 shown in FIG. 129.Severing of flap 2416 is optional and alternatively a hinge may beprovided by compressing flange 2428 with a profile so as to facilitateeasy hinging of flap 2416 and tray 2402 relative to each other.

Flap 2416 is arranged such that it can be “hinged” about the gap 2424such that flanges 2406 and 2408 contact directly with web 2404 materialtherebetween. Flanges can then be sealed together through web 2404 suchthat web 2404 material seals together in a desired manner. The apertures2422 and 2426 are positioned such that they become aligned after sealingof the flanges. Web 2404 material is then most likely to become lightlybonded together around the perimeter of apertures 2422 and 2426. Anadhesive may also be applied to the contacting surfaces of web 2404around the perimeters so as to cause substantial bonding and providing asubstantially liquid ‘tight’ seal there around so as to inhibit escapeof any liquids therebetween. This arrangement provides a directcommunication from space 2418 to any atmosphere external of the package,via apertures 2422 and 2426, space 2430 and recesses 2420. The locationof apertures 2422 and 2426, space 2430 and recesses 2420 are arrangedsuch that any liquids (or solid matter) that may accumulate within thepackage are inhibited from escaping from space 2418. With thisarrangement, gasses can communicate directly between space 2418 andwhile liquids and other solid matter is substantially restricted andheld within space 2430 or 2418.

Tray can be formed from foamed polyester or from expanded polystyrenefoam (EPS). Web 2404 may include a suitable grade of plasticized PVC(pPVC) which may be printed with various colors and graphics and a heatactivated, or pressure sensitive adhesive may also be applied during theprinting process or separately as desired and required to provide sealedfinished packages.

Completed packages 2434 can be stacked into master container 2412 untilit is filled. A lid including a gas barrier web can be then sealed tothe flanges of 2412 as described in U.S. patent application Ser. No.09/039,150. Packages 2434 are stacked such that the ridges 2436 on thebase of a first package “nest” adjacent to ridges 2438 of a secondpackage. A space can therefore be maintained between the bottom of thesecond package and the web and contents of the first package.

In a further embodiment, 2412 can be located within a chamber such as isshown in diagram 5100 prior to sealing the gas barrier web to theflanges of ‘MC’.

Embodiment 13

Referring now to FIG. 70, another embodiment of a tray with flapsconstructed according to the present invention is shown. FIG. 70 shows across-sectional through tray detailing a preferred profile. Rib 4420 isformed in flap 4422 adjacent to recess 4424. Rib 4420 is formed so as tocontact wall of tray as shown when flap is folded into position. Recess4426 is formed in the flap 4422 with an aperture or slot therein butdoes not contact the outer surface of the wall of tray and is providedwith space 4428 therebetween. A suitable adhesive such as a solvent isapplied to the surfaces of the flap 4422 and the wall of tray such thatwhen flap 4422 contacts the wall of tray, both parts bond together. Thebond between the flap 4422 and the wall of tray can be arranged tofollow a continuous path close to the perimeter of the flap 4422 andthereby provide a substantially liquid “tight” seal around space 4428.Each flap (4) can be applied with adhesive in a similar manner to thatdescribed for flap 4422 then, in like fashion, bonded to walls of trayto produce a finished tray. Apertures 4430 can be provided in the lowersection of the wall of tray such that liquids that may accumulate withinthe tray can pass through apertures 4430 and enter space 4428. Slots,slits or holes can be provided in recess 4424 such that directcommunication through recess 4424 into space 4428 and through apertures4430 can be provided. The surface of the flap and the wall of tray indirect contact with space 4428 can be treated so as to absorb liquidssuch as water, purge and blood.

Referring now to FIGS. 71-72, an enlarged cross-section through aportion of EPS sheet is shown and an enlarged cross-section through EPSsheet, after thermoforming and assembly of tray and flaps in finishedand bonded position, are detailed. In FIG. 71, a cross-section through aportion of sheet EPS foam with skin 4432 and skin 4434 is shown. EPSsheet, as shown in FIG. 71 can be extruded in normal production suchthat skin 4432 and skin 4434 is substantially nonporous and will resistabsorption of liquids, while the inner layer of EPS foam 4436 can beproduced so as to absorb liquids. In a preferred embodiment, the EPSsheet with skin 4432 and skin 4434 can be extruded and wound onto rollsin readiness for use in thermoforming and production of trays with flapsas shown in FIG. 52. In another preferred embodiment, the EPS sheetmaterial may include three layers of expanded polystyrene sheet where aninner layer of open celled foam, that has been arranged to absorbdesired liquids, is “sandwiched” between two outer layers of closed cellexpanded polystyrene sheet that will resist absorbing of the liquids.After thermoforming the trays with flaps, from the three layer materialor alternatively from material with outer skin 4432 and 4434 a solventor other suitable agent, can be applied by spraying, or any othersuitable method, to selected areas of flap(s) and wall(s) of tray suchthat only those selected surface areas, that will become enclosedbetween the flaps and the trays, after folding and sealing into therequired position, will have the solvent applied thereto. The solvent,or other suitable agent, can be applied in sufficient quantities to theselected surface areas, so as to dissolve the skin 4432 or 4434 atsurfaces 4438 and 4440, shown in FIG. 72 thereby exposing the inner,liquid and water absorbing EPS foam, for subsequent contact with anyliquids that may enter space 4428. In this way a finished tray, withflaps folded and sealed into the desired configuration, can be producedso that only the surfaces adjacent to and in contact with the space 4428will be substantially liquid and water absorbing. It can be seen thatany liquids that may be present on the inside of the tray can passthrough apertures 4430 and into space 4428. Liquids can then be absorbedby the exposed EPS foam in contact with the space 4428 however, due tothe liquid absorbing resistance of skin 4432 and 4434, the liquids maynot be visible to any person looking at the tray with flaps from outsidethe space 4428.

Embodiment 14

Referring now to FIGS. 73 and 74, another embodiment of a tray withflaps constructed according to the present invention is shown. Across-section through a finished package in shown in FIG. 730 and athree dimensional view of a finished package 3400, is shown in FIG. 74.The finished package 3400 includes a tray 3402 with perishable goodscontained therein and an outer cover of a substantially gas barriershrink material 3404. Apertures 3406 are provided in the gas barrierouter cover and a peelable, gas barrier label 3408 is hermeticallysealed over the apertures 3406. The finished package 3400 has spaces3410 and 3412 and other space contained within the outer cover 3404. Asubstantially oxygen free gas including any suitable gas, selected toextend the keeping qualities of the perishable goods, such as a blend ofcarbon dioxide and nitrogen, can be provided in the spaces inside thepackage 3400 after evacuating other gasses contained therein, such thatall the spaces are filled with oxygen free gas. The finished package canbe stored for a period of time and then the gas barrier label 3408 onthe tab 3414 can be removed by peeling, thereby allowing atmospheric gasto enter through the apertures 3406 and 3416 and into the spaces aroundthe perishable goods and contact the perishable goods.

Embodiment 15

Referring now to FIG. 76, another embodiment of a finished packageconstructed according to the present invention is shown. Across-sectional view with details of a preferred configuration includinga tray with flaps that are folded into the finished position and extendbelow the base of tray is shown in FIG. 75. As described in earlierembodiments of this present specification, a tray with flaps may includea rectangular flat base with radiused corners and upwardly extendedwalls that terminate at a flat horizontally disposed, common flange. Aspace or cavity is therefore defined between the walls. Flaps areconnected directly to the peripheral edge of the common flange at ahinge along a hinge line. A single flap may be attached to a single wallor alternatively up to four flaps may be attached, one to each wall. Thepackaging tray with flaps can be thermoformed from suitable plasticsmaterials such as expanded polystyrene (EPS) sheet. Flaps of variousconfigurations have been described herein with apertures convenientlyprovided to allow gas or air exchange therethrough while inhibiting andrestricting the escape of other matter such as liquids including bloodtherethrough. Such apertures and configurations allowing gas exchangetherethrough can be provided in this present embodiment if desired,however, the purpose of the description of this present embodiment is todisclose an improved packaging that will also protect the perishablegoods contents of the finished package when stacked together in a mastercontainer as shown in FIG. 16.

Referring now to FIG. 75, a loaded tray 3700 with flaps 3702 iscompletely covered with an outer cover 3704 and it can be seen that theouter cover 3704 is domed upwardly and is stretched over the uppersurface of the perishable goods 3706 such that the uppermost part of theperishable goods 3706 is extended above the common flange 3708 under theouter cover 3704. In this manner the perishable goods 3700 are heldfirmly to the base 3710 of tray 3700 by applying tension on the outercover material. An adhesive 3712 may be provided between the outer cover3704 and the common flange 3708 so as to seal, hermetically orotherwise, the outer cover 3704 to the common flange 3708 along a paththat will become an outer edge of the finished package. Additionally andas shown, adhesive 3712 may be provided between the flaps 3702 and thetray walls 3714 so as to seal the flaps 3702 in position to the walls asmay be desired, hermetically or otherwise. Adhesive 3712 may also beprovided between the underside of the base 3710 and between the base andthe inner surface of the outer cover 3704. Outer cover 3704 may includea suitably printed, heat shrinkable, stretchable, sealable, transparent,oxygen and gas permeable web of material with a “memory” that may beapplied after loading the perishable goods into the tray cavity. Theouter cover 3704 may be applied directly from a continuous web or rollof the material or alternatively may be fabricated into suitably sizedbags, such as those supplied by Robbie Manufacturing, Inc., prior tosealing over the loaded tray with flaps. The outer cover 3704 may besuitably perforated with apertures to allow gas and/or air exchangetherethrough and can be heat shrunk after sealing over the loaded traywith flaps by passing through a suitably adjusted heat tunnel.Alternatively, the outer cover 3704 may be applied from a continuous weband stretched during application thereof and then sealed to provide asealed outer cover 3704 that is stretched taught around and over theloaded tray with flaps as shown in FIG. 75.

FIG. 77 shows a cross-section of a tray after the application of theouter cover 3704, that may be manufactured from any transparent suitablematerial, but before stretching by depressing the outer cover 3704 intothe recess 3716 as shown in FIG. 78. FIG. 78 shows the samecross-section as in FIG. 134 after outer cover has been depressed so asto contact the adhesive between the base of tray and the inner surfaceof the outer cover 3704. By a mechanical device, the outer cover 3704,that is located adjacent to the underside of the base 3710 of tray, canbe depressed and stretched so as to contact the adhesive 3712 locatedbetween the inner surface of the outer cover 3704 and the under surfaceof the base 3710 of tray so as to provide bonding therebetween. A recess3716 can therefore be provided as shown. In this way, the outer cover3704 can be stretched over the entire surface of the tray 3700 withperishable goods contained therein. Therefore, when another finishedpackage of similar configuration is located and stacked above and onto asimilar lower package, the underside of the finished package will notcontact the upper surface of the dome of the lower package. In this waythe lower packages are protected from damage when stacked andtransported or when displayed in stacks at a point of sale to consumers.

Referring now to FIG. 79, a cross-sectional view through an assembledand finished master container 3722 is shown inside a closed and sealedcorrugated cardboard carton 3724. Two finished packages 3726 and 3728are shown inside the master container 3722. As can be seen, the extendedflaps of the upper finished package provide a recess to accommodate theupper surface dome of the lower finished package thereby providingprotection to the perishable goods contained therein. The mastercontainer 3722 may be thermoformed from a web of flexible, substantiallygas barrier, plastics material such as Curlon Grade 9315-II asmanufactured by Curwood of Oshkosh, Wis. and can be provided so as totightly hold the finished packages. A substantially gas barrier lid 3732that is provided from a web of plastics material such as Curlam Grade2500-K as manufactured by Curwood of Oshkosh, Wis., is shown heat sealedto the flange of the master container 3722. The seal 3734 between thelid and the master container will, most desirably, be a peelable sealthat can be peeled with relative ease by any person wishing to open thesealed master container. A desired gas 3736 is contained within thehermetically sealed master container and an oxygen scavenger 3730 islocated therein. Further, the lid of a master container may contain arelief valve to allow escape of any excess gas that may be released fromsolution in the meat and to accommodate for an expansion of the mastercontainer.

The sealed, gas barrier, master container 3722 is located in acorrugated cardboard carton 3724. The corrugated cardboard carton 3724may be manufactured by the Weyerhaeuser Corporation, of Tacoma, Wash.from 69140/69, 5100 flute corrugated cardboard and such a constructionwill withstand substantial loading.

An enlarged view of the seal arrangement is shown in FIG. 80 and analternative configuration showing flange of container in position afterfolding inwardly is shown in FIG. 81. In this embodiment the corrugatedcardboard carton is just large enough to contain the master containerbut the flange of the master container is folded inwardly to allow thesides of the master container to be in close contact with the innersurface of the carton, thereby reducing the size of the carton to aminimum.

The size of the master container and the corresponding size of thecarton can be suitably arranged to contain one or more finishedpackages.

Embodiment 16

FIG. 131 shows another embodiment of a tray constructed according to thepresent invention. The tray 1900 includes flap 1900. Flap 1900 isattached to tray 1902 along an outer edge 1904 of tray flange 1906 and afurther flap (not shown) can be attached to the outer edge along theopposite side of the tray which is parallel with the first flap and issimilar in operation thereto. After sealing of second and third webs toflanges 1906 and 1908, flap 1900 can be folded downwardly so that radius1910 in FIG. 132 engages with recess 1912. Flap 1900 includes a hingethat can be folded along a hinge line through an arc shown more clearlyin FIG. 132. Radius 1910 and recess 1912 “mate” and can be arranged sothat they “snap” into a matingly engaged position, thereby holding theflap 1900 firmly. Referring now to a cross-sectional view of the stackedtrays in FIG. 65, flap base 1918 is shaped so as to correspond withprofile of flanges 1906 and 1908 and a ridge 1926 is located along theexternal edge of flap base 1900 such that when a finished package isstacked above another similar package they will “nest” together and theupper tray is prevented from contacting the contents of the lower tray.The base of the tray can be formed with a profile providing an upwardlyextending depression that extends above the highest point of thecontents in the lower tray. In this fashion, the finished packages canbe stacked within cartons for distribution and shipped long distanceswithout causing damage to contents of the trays in the lower position.First web tray 1920 has recessed base to clear goods in the tray below.Lip 1928 can be heat sealed after folding of the flap by heat seal bars1930 to ensure that flap 1900 is retained in folded position as shown inthe stacked finished packages FIG. 133. Ridges 1932 can be formed intoflaps to improve rigidity and stability of the finished pack.

Embodiment 17

Referring to FIG. 82, another embodiment of a tray, 3100, with flaps isshown. A cross-section is shown in FIG. 83, where both flaps are foldedinwardly and the package has been inserted into a Clysar AFG shrink bag3114. The tray can be “stretch-wrapped” with PPVC as an alternate to aPP bag as shown in FIG. 83.

Tray 3100 includes a base with four upwardly extending walls,terminating at flanges 3104. Two flaps 3102, 3103 are provided such thatthey can fold inwardly. Recesses 3106 are provided in the flaps to allowcommunication of gasses therethrough. Tray 3100 further includes a baserim 3108 that extends around the perimeter of the base. Depressions 3110and perforations 3112 can be provided at the tray base 3126. Apertures3116 are provided in shrink bag 3114. Tray 3100 may be thermoformed fromany suitable material. Apertures 3116 provide direct communication fromexternal atmosphere through space 3118 and recesses 3118 to tray cavity.Perishable goods can be located into tray cavity and flaps 3102 foldedinwardly. Assembled tray and perishable goods can then be located withina polypropylene shrink bag, such as Clysar AFG shrink bag 3114 which isthen heat sealed and heat shrunk around the tray and goods to form afinished package. A plurality of finished packages may be assembled andstacked together to provide a group of assembled finished trays which isthen hermetically sealed within a substantially gas barrier mastercontainer as described in U.S. patent application Ser. No. 09/039,150with a gas barrier lid. When the finished packages are stacked, the baserim 3108 of one pack will rest directly above flaps 3102. In this way,finished packages can be stacked together without causing undesirabledamage to the contents of the package. Perforations 3112 absorb liquidsas described herein.

Alternatively, in a preferred embodiment, the Clysar AFG shrink bag3114, may be replaced with a stretch wrap material such as plasticizedPVC.

Referring now to FIG. 135 wherein a view of a section of tray 3100,after folding and bonding of the flaps to the tray wall, is shown. Aplan view of the scrap view section, prior to folding and bonding of theflaps, is shown in FIG. 134. A preferred method for production of trayswith flaps includes a thermoforming process and a “cut in place”procedure. The term “cut in place” is a common term used by thoseskilled in the art of tooling manufacture and use of thermoformingequipment. This term describes a thermoforming production methodincluding the use of a thermoforming tool with a cutting devicesincorporated into the tool so as to permit cutting of the subjectthermoformed component from a web of plastics material immediately afterforming and before ejection and removal of the component(s) from thethermoforming tool. The scrap view section shown in FIGS. 134-135details a single corner section of a four cornered tray such as the trayof FIG. 55, however, all four corners of the tray with flaps aresimilar. Referring again to FIGS. 134-135, flaps 5268 and 5270 are shownattached to a tray 5272 at a hinge 5274. The tray with flaps is shown inFIG. 134 prior to folding flaps and bonding. The tray with flaps isshown in FIG. 135 after folding of flaps and bonding. The flaps can beprinted by ink jet devices, prior to folding and bonding in the mannerdisclosed above with reference to FIG. 55. Adhesives can also be appliedby ink jet printers to the flaps and tray. Hinge lines 5276 and cutlines 5278 are all parallel and in the same plane. The cut lines 5278and hinge line 5276 terminate at points 5280 and 5282. If desired afurther hinge line 5284 provides devices to fold sections 5286, whichcan be folded and bonded to the base of tray. Panels 5288 and 5290 canbe printed with any information or graphics as may be desired and arearranged to be elevated and angled so as to be more easily visible by anintending purchaser of the tray with goods therein.

Referring now to FIG. 136, a cross-sectional view through a corner ofthe tray with flaps, after the flaps have been folded and bonded, isshown. The “cut in place” forming method allows a method to providewalls 5292 and 5294 that can contact each other, as shown, and be bondedtogether after folding the flaps into the finished position. In thisway, a substantially more rigid tray structure can be provided thatwould otherwise require a heavier wall section for trays that have notbeen provided with flaps as herein disclosed. With ink jet applicationof adhesives, as described herein, an efficient devices of economicallyapplying the minimum quantity of adhesives is provided. In this way,adhesives can be applied in a pattern that allows for maximum surfacearea bonding of trays and flaps while minimizing the quantity ofadhesive material required.

In yet another preferred embodiment, packaging including a combinationof features disclosed in any of the trays above may be combined toconstruct a finished package. For example, a package including a traywith any of the flaps disclosed herein may be constructed to providedesired features and inserted into either a Clysar AFG shrink bag oralternatively a stretch wrapped in a pPVC stretch film over wrap orshrink wrapped with printed Clysar AFG anti fog shrink film.

In yet another preferred embodiment, packaging including a combinationof features disclosed above may be combined to construct a finishedpackage. However, perforations may be provided in depressions to allowany free liquids to pass therethrough to a space between the base oftray and the outer shrink bag. Indentations may be provided in the under(or outer) surface of the tray that can allow open cells, that may bepresent in the EPS structure of the tray, to absorb the liquids.

Any of the foregoing trays with flaps will be used in a method toautomatically or manually performing the following steps:

Providing a tray with flaps, that has been thermoformed from expandedpolystyrene (EPS). The tray having dimensions that will provide for theefficient use of the internal dimensions and capacity of typical,refrigerated road and rail transport vehicles.

Trays will retain a substantially oxygen free gas within cell structureof the tray and/or exposing the tray and/or the tray material prior toand/or during thermoforming and production of the tray, to a gas thatexcludes oxygen and allowing the gas to exchange with any gassescontained within the cells of the EPS thereby substantially displacingany atmospheric oxygen from the cells or otherwise ensuring that gassescontained in the cell structure substantially excludes oxygen.

Providing perishable goods onto the base of the tray. The perishablegoods having been treated and processed to enhance the keeping qualitiesthereof.

Over wrapping the tray with goods therein with a web of gas permeablematerial such as pPVC, to produce a finished package and then seal theover wrapping web of gas permeable material to portions of the tray by aheat sealer or other suitable adhesives and then perforate the overwrapping web of gas permeable material at desired locations.

Placing the finished package or a plurality of similar finished packagesinto a gas barrier master container.

Displacing substantially all atmospheric gas, and particularlyatmospheric oxygen, from within the master container, with a suitablegas or blend of suitable gasses.

Sealing a lid over the opening in the master container to form ahermetically sealed package containing the trays with perishable goodsand suitable gas.

Placing the master container inside a carton such as can be manufacturedfrom corrugated cardboard and enclosing the master container.

Locating a plurality of closed cartons onto a standard (GMA specified)pallet (Dimensions of 40″×48″) so as to maximize the efficient use ofthe upper surface area provided by the pallet thereby producing a loadedpallet.

Storing the loaded pallet for a period of time in refrigerated space.

Delivering the finished pallets to a point of sale such as asupermarket.

Performing all aspects of the process in temperature controlledconditions

Embodiment 18

Referring first to FIG. 88, a tray 1000 is shown in a three dimensionaldisposition. The tray is arranged with a base 303 and four upwardlyextending walls terminating at a flange 901 with a cavity 110 surroundedby the walls. Each of the walls may be rigidly fabricated by bondingtogether, two or more layers (shown as 100, 101 and 102 in FIG. 89).Each layer is attached directly together or in series to the flange 901,of the tray, via hinges that allow folding of each layer together andagainst each other, prior to bonding the layers together, to providerigid wall(s). In this way the tray walls can be rigidly constructedwith higher compression resistance and at a lower cost than wouldotherwise be incurred for a single layer wall of a similar compressionresistant rigidity.

Referring to FIG. 90, a plan view of a thermoformed pre-form is shownwhich can be manufactured from any suitable material, of any suitablethickness but is most preferably thermoformed from extrudedpolypropylene sheet with a thickness of approximately 0.018″. Thepolypropylene sheet is then thermoformed to produce a pre-form, which isconstructed so that it can then be folded and bonded into a stackabletray profile. The pre-form consists of a cavity 110, with a series ofsemi-rigid flaps, all connected by at least a single hinge to the flange901. Cavity 110 has a base 303 with four upwardly extending wallsterminating at a continuous flange 901. Flange 901 may be arranged withfour straight sections connected via rounded corners but the otherpackaging tray configurations may be fabricated. At the outer perimeterof flange 901, adjacent flange flaps, 100, 301, 300 and 400 are attachedvia hinges shown as 88, 90, 89 and 87 respectively. Located at eachcorner of flange 901, and between each adjacent pair of adjacent flangeflaps, additional flaps are provided. Between adjacent flange flaps 100and 301 a pair of generally triangular adjacent flaps 101 and 99 arelocated but severed completely from direct attachment together by cut200. Flap 101 is attached to adjacent flange flap 100 via hinge 91 andflap 99 is attached to adjacent flange flap 301 via hinge 98. Similarly,flap 104 is attached to adjacent flange flap 301 via hinge 96 and flap206 is attached to adjacent flange flap 400 via hinge 94. Additionally,flap 205 is attached to adjacent flange flap 400 via hinge 93 and flap105 is attached to adjacent flange flap 300 via hinge 202. Finally, flap106 is attached to adjacent flange flap 100 via hinge 97 and flap 204 isattached to adjacent flange flap 100 via hinge 73. The pair of flaps 204and 106 are severed along cut 203, the pair of flaps 101 and 99 aresevered along cut 200, the pair of flaps 104 and 206 are severed along acut 201 and the pair of flaps 205 and 105 are severed along cut 202.Said flaps 101 and 204 can be folded toward each other until theycontact what becomes the inner surface of adjacent flange flap 100, andadjacent flange flap 100 can then be folded toward adjacent tray cavitywall 102 until the surfaces of flaps 101 and 204 contact a surface ofadjacent cavity wall 102. This can be repeated simultaneously,separately or in correspondingly opposite, adjacent flange flaps suchthat all flaps are folded and held together for bonding at any and allcontact points between the corresponding flaps and generally as detailedin FIG. 89.

Referring now to FIG. 89, a side wall of packaging tray shown in FIG. 88is detailed, after folding of flaps shown therein which can be bonded,by any suitable bonding means, at contact points 405, 406, 407, 408 and409. Bonding can be arranged to follow a path near what becomes aperimeter of adjacent flange flap 100 so as to hermetically seal space900 therein.

Referring now to FIG. 91, a cross section through flange 901, cavitywall 102 and adjacent flange flap 100, details a preferred embodimentwherein hinge 88 is located parallel to hinge 902 with an additionalflap section 905 between hinges 88 and 902. Adjacent flange flap 100 isbonded to wall 102 at 904.

Referring again to FIG. 90 in a preferred embodiment, an additional flap701 is shown attached to adjacent flange flap 301 via hinge 85 andadditional flap 700 is shown attached to adjacent flange flap 300 viahinge 86. Flaps may also be similarly attached via hinges to adjacentflange flaps 100 and 400 if so desired. In this arrangement pairs offlaps 104 and 206, 99 and 101, 204 and 106, 205 and 105 can be deleted,allowing flaps 701 and 700 to be folded respectively against what becomeinternal surfaces of adjacent flange flaps 301 and 300 prior to bondingthere together to provide a structure generally similar to that shown inFIG. 89.

Referring now to FIG. 92, a plan view of a preferred pre-form is shown,wherein a centrally located cavity 12 is connected via hinges 17, 19, 23and 18, to flaps 11, 13, 14 and 16 respectively. Additional flaps 10 and15 are attached via hinges to flaps 11 and 14. Ribs can be provided toall parts of the tray cavity, walls and flaps and can be arranged in anysuitable profile so as to maximize rigidity of the finished tray but areshown only in flaps 10 and 15.

Referring now to FIG. 93, two pre-forms are shown stacked and nestedtogether. In this way pre-forms can be manufactured and thenconveniently stacked in a nesting configuration, minimizing the volumeof space required during storage and shipping thereof. Pre-forms canthen be fabricated at the point of use for packaging goods.

Referring now to FIG. 94, a cross section through a tray assemblyfixture arranged to fold and bond pre-forms in an enclosed chamber isshown. Only one view of the assembly fixture is shown which is rigidlyconstructed from suitable materials wherein a base frame 38 is connectedto a platen 37. Base frame 38 and platen 37 can be securely connectedthere together by any suitable means but most preferably by way of aquick release arrangement so as to allow the rapid separation of the twocomponents. In a preferred embodiment, several similar assembly fixturescan be attached to a horizontally disposed continuous conveyor andarranged to operate automatically as a complete machine and this will begenerally described in a later part of this disclosure. Platen 37 issecurely attached to a profiled fixture 39, which is shaped tocorrespond with the internal, cavity surface profile of a pre-form suchas shown in FIG. 92. A pre-form 35 is shown in position and mated withfixture 39. Part 36 is hinged at 151 and part 33 is hinged at 150. Parts36 and 33 are arranged to dimensionally correspond to the flaps ofpre-form 35, and can be attached to a suitable driving arrangement suchas pneumatic cylinders that will drive each part to close in a sequenceas required. Part 36 is shown in an open disposition whereas part 33 isshown in a closed position and firmly holding a flap of pre-form 35against a wall thereof. A source of vacuum may be attached to fixture 39or single chamber (32 and 31) so as to assist in securely holding thepre-form in place during folding and bonding of flaps. After flaps havebeen bonded into position the vacuum may be released to allow easyremoval of the folded and bonded tray. Additional hinged parts (notshown), similar to 36 and 33, may be attached to other sides to fixture39 as may be required to correspond with additional flaps that may beattached via hinges to pre-form 35. A typical pre-form is shown in FIGS.92 and 93. All hinged parts 36, 33 and any others can be arranged tofold flaps against the side walls of pre-form 35 and to hold thereagainst securely during bonding of flaps to correspondingly adjacentside walls. A single chamber is shown in two parts, 31 and 32, that canbe opened and closed as required to allow pre-forms such as 35 to belocated on fixture 39 and sequentially unloaded by any suitable means inan automated and continuous process. The single chamber (31 and 32) isattached to a shaft 30, which in turn is attached to a drive such as apneumatic cylinder, which can provide alternating opening and closing ofthe chamber. Ports can be provided in the single chamber with valvesarranged to allow any suitable gas at any suitable pressure therein andconnection to a suitable source of vacuum. The single chamber can bearranged to close over fixture 39 after locating a pre-form (35) thereonand a seal such as ‘O’ ring 34, can be installed along the contactingface between the single chamber (31 and 32) and platen 37. In this way,an enclosed and substantially gas tight enclosed space 46 can beprovided. Prior to closing the single chamber against platen 37, hingedparts 36 and 33 can be activated by driving air driven cylinders. Afterclosing the single chamber, space 46 can be substantially filled withany suitable gas at any suitable pressure via valves and ports (notshown) and to ensure that cavities between flaps and cavity walls arefilled with the selected gas and thereby substantially excludingatmospheric oxygen. Hinged parts 36 and 33 can be arranged to carry anysuitable sealing mechanism, such as RF welding and arranged to bondflaps to side walls of pre-form 35 directly. In this way cavities suchas space 900 described above and in association with FIG. 89 can befilled with any suitable gas at any suitable pressure. In summary, apreferred sequence of apparatus operation, as shown in FIG. 94 can be asfollows:

A. Provide a pre-form 35, locate on fixture 39, and apply a vacuumsource to hold the pre-form securely to fixture 39.

B. Apply any suitable adhesive to selected surfaces of flaps of pre-formand fold hinged parts such as 36 and 33 so as to fold and close flapsagainst the side walls of the pre-form. [Hinged parts 36 and 33 may bearranged with a means to partially close and thereby allow substantiallycomplete evacuation of air or gas therefrom prior to bonding].

C. Close single chamber over pre-form and seal chamber against platen37.

D. Evacuate space 46 and provide any suitable gas at any suitablepressure therein.

E. Seal flaps to side walls of pre-form.

F. Open chamber and allow removal of pre-form with flaps bonded to sidewalls.

Referring again to FIG. 94, assembly fixture detailed therein can bearranged in groups wherein each assembly fixture is attached, via quickrelease connection, to a pair of parallel horizontally disposed,continuous chains, with a driving motor such as a servo electric motor,horizontally disposed to provide a conveyor. In this way a completemachine can be arranged with the upper section thereof, enclosed and asuitable gas provided in enclosure, such that when pre-forms are locatedon fixtures (39), if so desired, the gas in contact with pre-forms isoxygen free.

Referring now to FIG. 95, a side view and end view of two finishedpackaging trays 40 and 41 stacked together are shown. Ribs 43 and 42locate interlock with the base of the upper tray.

Referring now to FIG. 97 and FIG. 98, another preferred packaging tray(190) embodiment is shown with a cross sectional view 2-2 therethrough.Tray 190 may be manufactured from any suitable material but in thisinstance a material such as polyethylene is preferable. A cavity 61 issurrounded by upwardly extended side walls 64, 67, 68 and 60 allterminating at flange 60. Flaps 67 and 64 are visible and ribs 65 and 67are shown in flap 67 and ribs 62 and 63 are shown in flap 64. Flaps, 67and 64 (including those not visible), have been hermetically bonded toside walls of tray. Referring now to section 2-2 in FIG. 98, a crosssection through ribs 65 and 66 is shown. Hinges 70 and 71 are arrangedto allow folding of flap 67 against wall 80. Hermetic seals are shown at72, 75 and 78. Hermetic seals shown as 72 and 75 follow a pathcompletely around the perimeter of rib 65 and hermetic seals shown as 75and 78 follow a path completely around the perimeter of rib 66. In thisway a spaces 73 and 76 can be completely enclosed and hermeticallysealed separately from each other. However, prior to bonding ribs so asto enclose and hermetically seal spaces 73 and 76, any suitable gas suchas carbon dioxide at any suitable pressure but most preferably at arelative high pressure, such as 80 psi, can be provided therein. In thisway a rigid tray can be manufactured with reduced material content andtherefore at relatively lower cost.

Referring now to FIG. 99, a tray 180 with lateral ribs arranged in asimilar manner to those (62, 63, 65 and 66) disclosed in FIG. 7 isshown. Section 3-3 shows spaces 86 and 87, enclosed and hermeticallysealed within ribs 94 and 98, along seals 84, 88 and 89 which can befilled with high pressure gas such as CO₂. Hinges 82 and 83 are locatedso as to provide an outwardly extending flange, after folding flapagainst wall 85, and to which a web of material shown as lid 81 can behermetically sealed so as to fully enclose cavity 181. Apertures such as99 can be provided to allow liquids to enter cavity 90 and seal at 91prevents escape of such liquids from space 90. Ribs such as 93 can beprovided.

Referring now to FIG. 84, two thermoformed trays 200 and 201 are shownin a partially nesting disposition. The profile of tray 200 is arrangedwith upwardly extending walls terminating at flange 196 with ribs 199and 184, formed into the walls. Ribs formed in tray 200 such as 199 and184 extend inward toward the center of cavity 210 and ribs such as 198and 183 in tray 201 extend outwardly away from a centrally disposedcavity.

Referring now to FIG. 85, the two trays 200 and 201 in FIG. 84 are shownsealed together to form a single tray 1001. Flanges 196 and 197 arehermetically sealed together around the full length of what has become apath close to the tray perimeter. FIGS. 86-87 show details of enclosedspaces such as 188, 187 and 189. Ribs are also hermetically sealed suchthat ribs formed in the walls of the inner tray are sealed against thecorresponding rib in the outer tray to provide fully enclosed spacessuch as 187 shown in FIG. 87, that can be filled with high pressure gas.Seal paths 190 and 191 are shown as examples of hermetic sealing andenclosing of spaces such as 187. FIG. 87 shows rib 184 hermeticallysealed to rib 187, at 186 and 185 enclosing space 187.

Referring now to FIG. 101 a cross section through a tray similar to tray200 shown in FIG. 84 is detailed in a preferred embodiment wherein atray with a base 1100, and upwardly extending walls 1102 terminating atflange 1103 is provided with rib 1102 formed therein. A separatelyformed rib 1101 is shown adjacent to rib 1102 in a position prior tobonding and also after bonding to tray wall along seal path 1105. Ahermetically sealed and enclosed space 1106 can be filled with highpressure such as CO₂. In FIG. 102, a cross section through ribs 1105 and1102 is shown with space 1106 enclosed therein.

Referring now to FIG. 103, a thermoformed tray, 12102 is shown in athree dimensional view located above a form cut blank, 12100. Ribs areprovided in the base 12104 and walls, 12108, 12107, 12106 and 12105 in avertically disposed arrangement. Any suitable rib configuration may beprovided in the walls and base of any suitable size tray, but mostpreferably rigid ribs such as 12103, as shown in FIG. 103, are providedwith the recess accessible from the outer side of each wall, with theridge extending inwardly. Trays 12102 and blanks 12100 can bemanufactured in any required size, from any suitable material but mostpreferably would be produced from mono-layer extruded polyethyleneterephthalate (PET) sheet. PET sheet may be extruded with multiplelayers and both or a single outer layer may be provided with enhancedheat or RF (radio frequency (RF) or micro wave) sealable properties.Enhanced RF sealability may be provided by including any suitableadditive such as suitable metallic elements or compounds in the outerlayers, by blending into the polymer prior to extrusion.

Hinges shown at 1204, 1208, 1209 and 1207 are arranged so that flapportions 1200, 1201, 1202 and 1205 are all attached, thereby, to centralrectangular portion 1203. In this way flap portions can be foldedupwardly about hinges so as to contact the walls of tray 12103. Flap andbase portions of blank 12100 can then be sealed to the walls of tray12102 so as to provide a hermetic seal around the perimeter of each ribafter providing gas such as CO₂ at an elevated pressure in the recess ofeach rib. In this way a rigid tray can be manufactured withsubstantially less material content than would otherwise be required fora tray manufactured from a single component.

Embodiment 20

Referring now to FIGS. 268-270, a preferred tray with flaps is shown.Tray 7202 includes a crest 7200 constructed on the perimeter of the trayopening on a wall of the tray 7202. A similar crest is also constructedon opposite sidewall so as to form two convex areas having a firstradius. Referring now to FIG. 269, a flap is shown with a flap base 7204having a concave indentation 7204 of a second radius. When folded, as ina finished package, flap base 7204 is substantially level with the traybase 7216. Preferably, two such flap bases are provided, each inopposing sides from the other. Referring now to FIG. 270, a plurality offinished stacked packages using the trays of FIG. 268 is shown.Preferably, the flap base concave indentation radius is smaller than theradius of tray crest, so that when stacked, flap base of upper tray 7212makes contact with tray crest of lower tray 7214 at two locations 7208and 7210. In this manner, trays are prevented from rocking back andforth if only one contact point is provided. Preferably, a space isprovided between upper tray 7212 and lower tray 7214 which is also shownin FIG. 270. In this manner, the underside of tray base 7216 isprevented from touching the sealed or overwrapping web on lower tray.The sealed or overwrapped web material substantially holds the freshmeat portions to the tray base. Preferably, the web material is oxygenpermeable. Finished packages can thus be stored and packaged in any ofthe master containers disclosed herein. The disclosed tray profileallows stacking of several layers of trays in a vertical stack, whereineach loaded and over wrapped tray is located directly above and incontact with a lower tray to maximize density of a finished mastercontainer. Preferably, the profile of the flaps is an upwardly archedbase that corresponds with the profile of the tray upper flange profile.Preferably, ground meat is extruded with a profile that corresponds tothe inner profile of the cross section across the length of the traysuch that when loaded into the tray, the upper surface of the extrudedgrinds portion is in firm contact with the tray over wrap so that itholds it in place and slightly below the upper edge of the flanges. Theend flanges are arched to match the arched base and end flap profile ofthe lower tray profile. Continuous bonding of each flap around it'sperimeter to ensure that the end edge butts up and contacts the adjacentflaps provides for maximum structural stability and minimum twist afterfabrication and bonding. Thus, the double walls (inner cavity and outerflap) improve crush resistance.

Trays with Iron Powder

Powdered iron is often used as an agent for scavenging free, residualoxygen gas in packaged perishable, foods; for example Keplon Co., Ltd.of Kanagawa, Japan have manufactured deoxidizers such as Keplon-TY forthis purpose. As exemplary of the application of the method to thepresent invention, reference will be made with regard to FIG. 49, but itshould be readily apparent that the method herein described can beeasily applied to any of the trays made from the present invention.Powdered iron may be applied to the inner surface of the outer cover4140, in such a manner so as to become activated by water that may beprovided in the adhesive layer 4136. Furthermore when theoutside-surface of foam 4142 (see detail in FIG. 49) is arranged to havea capacity to absorb liquids, such liquids can be retained andsubstantially prevented from escaping from within the finished package.Additionally, a suitable adhesive can be provided between the trayflange rim 4144 and the outer cover 4140 where the continuous flange rim4144 is in contact with the outer cover.

Powdered iron can be used as an oxidizing agent and removal of oxygengas from within a hermetically sealed, gas barrier package. Powderediron may be applied, in combination with other suitable sealingsubstances and agents, to the surface and most preferably to an innersurface, of the outer cover 4140 at locations that will become in directcontact with underside of the base of tray. The iron powder can beapplied to outer cover 4140 in such a manner so as to allow subsequentactivation by water that may be contained in the adhesive layer 4136when applied to the under surface of the base of tray, at the time ofover wrapping the tray with perishable goods therein, and when cover4140 contacts the base of tray.

Prior to application to the inner surface of the outer cover 4140, thepowdered iron particles may be coated with a suitable coating includinga suitable protecting substance or blend of protecting substances, thatcan provide a protecting layer over the complete outer surface of theiron powder particles thereby protecting and isolating the iron powderparticles from direct contact with water or other substances that maycause the iron powder to oxidize. The protecting layer can therebyremain in the protecting condition until the coating is altered to allowwater to permeate therethrough or otherwise contact the iron particles.The coating may be altered at, for example, a convenient time aftercomplete or partial assembly of the finished packages by exposing to anelectromagnetic field of such intensity or in such a manner as to inducegeneration of heat in the particles of iron. Generation of heat in theiron particles by, for example, exposure to an electromagnetic field,may be induced by a suitable frequency of alternating electric current.Generation of heat in this manner may cause the protecting coating torelease water or allow water from adhesive layer to contact and therebyactivate the powdered iron to oxidize. Oxidation of iron powder in thisway can result in absorption of residual oxygen that may be presentinside the master package. Any suitable coating that possesses therequired chemical and physical properties may be used to coat the ironpowder. In this way the iron powder particles can be maintained in aprotected and “dormant” condition until required to absorb oxygen suchas after sealing of the package and when enclosed within a mastercontainer.

In this way air and gasses can be removed from the finished and sealedpackages by evacuation and then replaced by gas flushing with a desiredgas, while liquids such as blood cannot readily escape. Furthermore,gasses can readily flow through the communicating passage from inside tooutside of the package (but still inside the master container) to enablerapid equilibration of gasses when oxygen gas is released by reductionof oxymyoglobin after sealing of the master container. Any residualoxygen that may remain present in the sealed master container can beabsorbed by the oxidizing iron particles after activation with theelectromagnetic field, causing release of water or other suitablesubstances and direct contact with the iron particles.

Referring now to FIGS. 137-139 three cross-sectional views of selectedsections of EPS trays with flaps are detailed. FIG. 137 shows a sectionof a tray with a flap attached at a hinge and where the flap is “open”and not folded so as to be in contact with tray 3500. FIG. 138 shows aflap folded into a finished position and contacting tray 3500. The flapmay be formed with a recess 5506 that can be a arranged to be acontinuous recess that follows a path close to the perimeter of theflap. The tray can be arranged to have a ridge 5508 that follows a pathcorresponding to the recess 5506 such that when the flap is folded aboutthe hinge so as to intimately contact the tray wall and base, the ridge5508 will mate with the recess 5506, as shown in enlarged view of FIG.139. Accordingly, the flaps with heat activated adhesive applied inrecesses 5506 can be folded, as shown in FIG. 138, so as to causeintimate contact with the tray base 5512 and/or walls 5514 therebyproviding a tray with folded flaps. The tray with folded flaps can beheld in such a folded condition so as to hold ridges 5508 firmly againstadhesive and in continuos contact with 5516 along the full length of theridge and recess. The tray with folded flaps can be transferredautomatically into and through a microwave oven source of heat such thatadhesive 5516 is activated by exposure to a suitable level of microwaveheat source and thereby bond the flap and tray together at ridge 5508and recess 5506. The bond can be arranged along a continuous path andenclose the space between the flaps and the tray so as to provide asubstantially liquid tight seal. Selective heating of adhesive 5516 canbe provided by microwave or magnetic field devices so as to causebonding without application of excessive heat that could otherwise causeundesirable distortion to the EPS tray. Any suitable heat activatedadhesive may be provided by any suitable device. In another preferredembodiment the heat activated adhesive may be provided in the recess5506 by computer controlled robots such as in the form of a heated andsoftened continuous extruded bead that may be subsequently heated so asto provide good bonding in the recess, followed by cooling thereof toprovide hardening of the heat activated adhesive. Heat activatedadhesives may be applied to the tray with flaps or any other suitablepackaging materials by any suitable method prior to bonding. Subsequentexposure to microwave or other suitable source of heating, that can beselectively applied in such a manner so as not to cause undesirabledamage or distortion to the packaging materials, can produce a packageaccording to the present invention. A suitable device for adhesiveapplication to selected surfaces of packaging may be provided by theknown process of ink jet printing.

Any suitable substances for enhancing the keeping qualities of goods canbe provided into the spaces between the flaps and the tray walls. Water,liquid and purge absorbing substances can be provided in those spaceswhich may be arranged so as to be non absorbing prior to exposure to andcapable of absorbing liquids only after exposure to microwaves or amagnetic field.

Apparatus for Applying Adhesives and Iron Powder to Trays

Trays constructed according to the present invention may have one ormore features which lends itself to be stackable or allows thechanneling of gases, while retaining liquids. Trays with flaps arepreferably constructed with adhesives to form the finished tray. Thisdescription therefore provides a method and apparatus for applyingadhesives and other substances to the trays.

Referring now to FIGS. 140-142, an apparatus constructed according tothe present invention that can be used to apply substances to thesurface of packaging materials, such as EPS trays, for bonding theretois shown.

In FIG. 140 a cross-sectional view through a diagrammaticallyrepresented apparatus is shown where a horizontally disposed motordriven conveyor 5400, can be intermittently indexed by driving for a setdistance or movement. Magnets 5402 can be located in the conveyor 5400in convenient positions. A web of tray 5404 impressions can be arrangedto mate with the conveyor 5400 and can thereby be carried by theconveyor. The distance traveled by the conveyor in each movement orindex is equal and can be arranged so as to carry a single trayimpression a distance equal to the machine direction length of eachconsecutive tray impression. Such an arrangement can therefore positioneach tray impression adjacent to a station or processing device for adesired period of time followed by further movement of the trayimpression to a subsequent station to allow further processing. FIG. 140shows a first, second, and third station which are marked 5406, 5408 and5410, respectively. Station 5406 is arranged to apply an adhesive 5412by a nozzle spray device 5412 to an exposed surface of the trayimpressions. Station 2 is arranged to dispense iron powder 5410 or othersuitable substance, from a conveniently located hopper 5418 with valve5420, directly above an exposed surface of a tray impression that hashad adhesive applied thereto. Magnets 5402 which may be arranged aspermanent or as electrically induced (electromagnets) magnets, areconveniently located in the conveyor such that when iron powder 5416 isdispensed from hopper 5418, it will be attracted toward the magnets 5402and be deposited in a pattern on the exposed surface of the trayimpressions. The pattern of iron powder deposits can be determined bythe profile/shape of the magnets 5402 which can be adjusted as requiredto provide a suitable pattern. The powder 5416 may be then bonded byadhesive to the tray impression 5424. Third station 5410 can be arrangedto apply drying or curing, such as a radiant heater 5422, to theadhesive sprayed and tray impressions 5424 and thereby cause settingand/or drying of the adhesive applied at the first station 5406 withiron powder 5416 thereto. The iron powder applied at second station 5408can thereby be suitably bonded to the tray impression 5424. Additionalstations may be arranged, adjacent to the conveyor 5400 so as to applyadditional layers of adhesive and/or additional substances as may berequired.

Referring now to FIG. 141, a cross-sectional view through a section of adiagrammatically represented apparatus is detailed and showing aprofiled vacuum plate mating with a section of an EPS tray that islocated between a manifold 5426 and a vacuum plate 5428. Manifold andthe vacuum plate can be attached to moving devices such as pneumaticcylinders that can be operated as desired to move the vacuum plate andthe manifold toward and away from each other in an automated cycling andrepetitive sequence. The vacuum plate and the manifold can be closedtogether so as to conveniently clamp an EPS tray (or other material)therebetween for a period of time. The EPS tray can be arranged withperforations 5430 therein. The perforations can be located in a recessshown as 5432 in the enlarged view in FIG. 141. The vacuum plate can beprovided with vacuum ports 5434 therein and located so as to provideconnection between the under surface of EPS tray and a suitable vacuumsource 5436. In this fashion a vacuum source can be applied to the undersurface of the EPS tray with communication through the perforations5430. The manifold can be provided and arranged with suitable openingsthat connect selected exposed sections, such as sections 5440 and 5442,on the exposed surface of the tray to a source of powdered substances“ADSP”. In this way powdered substances, such as heat activatedadhesives, can be provided into the manifold openings and by applying avacuum source to the underside of the tray, the powdered substances canbe deposited onto the exposed surfaces of the tray and/or in recessessuch as recess 5432. After the powder 5414 has been deposited into therecesses 5432 the manifold and vacuum plate can be opened pneumaticallyallowing the EPS tray to be removed therefrom and subsequently passedinto and through a suitable heat and/or suitable energy source, such asa microwave oven. The powder 5414 can be arranged to contain substancessuch as water or suitable metal elements, so that when the tray withpowder 5414, 5444 is exposed to a microwave, magnetic field or othersuitable source of heating energy, the powder will be heat activated andbond together and to the surface of the tray and in the recess 5432. Thepowder 5414, 5444 can thereby be securely bonded to the EPS tray atselected locations on the exposed surfaces of the EPS tray. This methodof using a magnetic field, microwave or other suitable source of heatingenergy can selectively heat the powder 5414, 5444 without application ofexcessive heat to the EPS tray. Powder application apparatus includingthe vacuum plate and the manifold material clamping devices with allrequired driving and controlling apparatus can be integrated into atypical thermoforming equipment, such as an Irwin Magnum or a Commodore730-12 MM continuous thermoformer (as manufactured by Commodore MachineCompany of Bloomfield, N.Y. The disclosed powder application withselective microwave heating of the powder 5414, 5444 can be locatedbetween a thermoforming station and a trim press of the thermoformingequipment. In this way, a heat activated adhesive can be applied tospecific locations of any suitable material such as the flaps and/ortray walls of EPS trays such as a tray with flaps described above.

Apparatus for Applying Adhesives and Iron Powder to Outer Cover

Referring now to FIG. 143 an embodiment of apparatus constructedaccording to the present invention to apply adhesive materials andpowdered iron to a web of material such as stretch or shrink wrappingmaterials is shown.

The description disclosed herein provides details of a method andapparatus for producing stretch or shrink wrapping material that can beused in the production of those packages disclosed above, having anouter cover web material. The stretch or shrink wrapping material withpowdered iron attached thereto absorbs any residual oxygen that may bepresent within the master container and also the cell structure of EPSmaterials used in the production of the finished package.

The apparatus shown in FIG. 143 includes a series of rollers, a hoppercontaining powdered iron, a tray containing solvent based adhesive, anoven and a continuous web of outer cover material 4300 that is arrangedto follow a path over rollers, through oven and onto a web winderassembly as shown. The sketch includes a cross-section through theapparatus.

A suitable tension is applied to web outer cover material 4300 which isarranged to follow a path over idler roller 4302 and then to contactimprint roller 4304, over roller 4306, between oven segments 4310 andonto a roll 4310 at a web winder assembly 4312. Web 4300 is wound ontoroll 4310 by web winder assembly 4312 at a suitable tension and speed.In this manner, imprint roller 4304 is arranged to apply a suitableadhesive, which may be solvent based, onto web 4300 in a registeredprint pattern and in rectangular areas 4314 as shown in FIG. 144 where asection of finished web material 4316 is detailed in plan view, with across-sectional view shown in FIG. 145, after processing through theapparatus shown in FIG. 143. The method includes transferring theadhesive 4318 from the tray 4320 via contact with roller 4322 which inturn transfers the adhesive to transfer roller 4324 which in turntransfers the adhesive onto the imprint roller 4304. Transfer of theadhesive from the transfer roller 4324 to imprint roller 4304 occursonly at selected areas on the roller 4304 that correspond with therectangular areas 4314 such that areas 4314 only are imprinted with theadhesive applied thereto and leaving other sections of the outer cover4300 free of adhesive. The outer cover web material 4300 can be printedwith information and graphics as required on the opposite side of theweb to the applied solvent based adhesive in rectangular areas 4314 andin registered relationship to the rectangular areas 4314, such that whenthe web 4300 is cut by slitting along the length of the outer cover web,and wound conveniently onto rolls, the web 4300 can be applied, in anearlier described manner to cover the finished packages and with therectangular area 4314 adjacent to and in direct contact with the base oftrays.

Referring again to FIG. 143, powdered iron is dispensed from the hopperevenly across the web, so as to fall directly downward toward web 4300above roller 4306. Roller 4306 includes a tube manufactured, mostpreferably, from a nonmetallic material such as fiberglass and iscylindrically ground on both internal and external surfaces to provide afinished tube of specified internal and external diameters. Externaldiameter is arranged so as to have a circumference equal to two (×3across the web) consecutive imprints (6 imprints in total) ofrectangular areas 4314 per single revolution of the roller 4306.Correspondingly, during a single, full revolution of the roller 4306, 2times 3 imprints (6) are applied to the web 4300. Corresponding to theimprint areas 4314, magnets 4305 are located and fixed to the internalsurfaces of roller 4306 in a pattern that corresponds with therectangular areas 4314 in positions such that when the powdered iron isdispensed from the hopper it is drawn by the magnets so as to bedeposited substantially within the specified rectangular areas 4314.When the powdered iron contacts the areas 4314, on the web 4300, thepowdered iron bonds to the solvent based adhesive applied by imprintroller 4304. The powdered iron thereby becomes fixed to the web 4300 byadhering to the solvent based adhesive. The web 4300 then passes betweenthe oven segments 4308 that are arranged to have sufficient capacity tocure and dry the solvent based adhesive prior to further processingand/or winding of web 4300 onto the roll 4310 by web winder assembly4312.

Web 4310 may be further processed by applying solvent based adhesiveonto rectangular areas 4314 after the powdered iron has been applied andcured together therewith by passing through the oven segments. Thisprocess may be repeated several times and as may be required to producethe most effective finished outer cover web 4304 materials.

In yet another preferred embodiment other web materials such asperforated polyethylene and polyester may be laminated to web 4300 andover the powdered iron. Most preferably the powdered iron will therebybe applied and retained between the outer cover 4300 and thepolyethylene and/or polyester webs in such a manner so as to allowoxygen to transmit through the outer webs and contact the powdered ironand after reacting therewith, inhibiting the escape of any odor that maybe produced as a result of oxygen reacting with the powdered iron,and/or other substances contained therein. Solvent based adhesive canalso allow transmission of oxygen therethrough while inhibitingtransmission of odors therethrough.

Alternative oxygen absorbing materials that are suitable for theapplication may be applied with the iron powder or in place thereof.

The finished web material 4316 can be slit and wound onto convenientlysized rolls for subsequent use as the outer cover of packages similar tothe finished packages described above.

Tray Sealing Apparatus

Webs suitable for use as trays and covers have thus far been disclosed.A method for sealing a cover to a tray web now follows.

Referring now to FIG. 146, a tray sealing apparatus is shown to producepackages, including a tray, a web and perishable goods contents shown asground meat. The perishable goods may be portions of beef, pork, or anyother suitable perishable goods. A horizontally disposed, continuousconveyor 2326 including a number of carrier plates 2302 suitablyattached to chains is arranged adjacent and below a series of stations.The conveyor 2326 is driven by a driver that intermittently indexes in aforward direction indicated by arrow 2328, at a rate of one carrierplate per index. Trays 2300, as described in any of the previousembodiments, are dispensed into apertures in the carrier plates 2302 ata first station generally denoted by the number 2330. With eachprogressive forward indexing movement of the conveyor, stations willperform a function. Cutting devices at a second station generallydenoted by 2304 severs flaps. Product such as portions of ground beef isloaded into the tray at a product loading station 2306, and a web ofmaterial 2308 is heat sealed to flanges at a heat sealer station 2312.Scrap material from web 2308 is wound onto scrap roll 2310. Preferably,tray apertures are provided by heated pin devices at station 2314. Flapsare turned over by rotating about hinge so as to then locate flangesadjacent to tray 2300, at flap turning station 2316. Preferably flangesof flaps are then sealed to flanges of tray at station 2318 and flangetrimming is performed as may be required at station 2320. Labeling isdone with a tray labeler at station 2322. The finished tray withperishable goods packaged therein is ejected from the conveyor at anejector station 2324.

Referring now to FIG. 14, a preferred tray constructed according to thepresent invention is shown in an inverted position. The tray 2402includes those apertures made by the apparatus of FIG. 83.

Method and Apparatus for Evacuating Master Containers

Trays constructed according to the present invention provided structureswhich allowed the evacuation of ambient atmosphere and flushing withinert gases. Trays according to the present invention are also stackableatop one another to allow placement within a master container.Therefore, a method for evacuating a master container appropriatelyfollows.

Referring now to FIG. 148, details of a vacuum and modified atmospherepackaging and sealing apparatus is shown. The apparatus 3564 can be usedto hermetically seal a web of material over the open end of a plasticbag or pouch. The web of material and pouch may include substantiallygas barrier materials and the hermetically sealed pouch and web can beused for any useful purpose, such as vacuum packaging meat primalportions or to contain one or more retail packages, thereby providing amaster package which can be subsequently packaged inside a suitablysized shipping carton.

The apparatus 3564 includes a lower vacuum chamber 3566, that issuitably mounted with a driver (not shown) attached to a shaft 3568, anupper vacuum chamber 3570 with a moveable heat bank 3572, attached to adriver (not shown) via shaft 3574 and suitably mounted between the upperand lower vacuum chambers, and a web unwinding assembly 3576 arranged toallow controlled unwinding of web material 3578 from roll 3584. Aconduit 3582 is connected to upper vacuum chamber 3570 and a conduit3584 is connected to lower member 3566. Both conduits 3582 and 3584 canbe connected to a suitable source of vacuum and/or supply of suitablegas. The upper vacuum chamber 3570 is fitted with a suitable rubberizedsealing member 3586 which is attached to the rim of the vacuum chamber3570 and a corresponding and matching sealing member 3588 is mounted, insimilar fashion, to a rim of member 3566, so that when the upper andlower vacuum chambers are closed and held together, members 3586 and3588 are in intimate contact with each other, thereby providing anenclosed vacuum chamber that is sealed from ambient atmosphere withspace 3590 contained therein. Web unwind assembly 3576 is arranged tounwind material 3578 from roll of material 3580, as required, and locatethe web between the upper and lower vacuum chambers. In this waysuitable portions of the material 3578 can be automatically unwound byweb unwind assembly and clamped between sealing members 3586 and 3588.Referring now to FIG. 150, it can be seen that rim at 3588 is extendedbeyond rim at 3592 such that when web 3578 is clamped between members3566 and 3570 a space 3594 between the web 3578 and the rim at 3592 isprovided. Sealing members 3588 and 3586 are parallel and follow adjacentpaths at parallel perimeters of the respective members 3570 and 3570along corresponding rims at 3586 and 3588, such that when the vacuumchambers 3570 and 3566 are closed together a completely sealed anddefined space 3590 is provided therein. In this way space 3590 can beevacuated and substantially all air contained therein removed, asrequired, and then space 3590 can be filled with suitable gas such asnitrogen, CO₂ or any other suitable blend of gases, at a suitablepressure, via conduits 3582 and 3584.

Referring now to FIG. 149, a three dimensional sketch is shown of thelower vacuum chamber with a portion of the lower vacuum chamber shown inFIG. 150. The vacuum chamber can be manufactured from any suitablematerial such as stainless steel. It can be seen that vacuum chamber3566 includes a rectangular profiled component with vertical walls and arectangular depression 3596 provided therein; two parallel andcontinuous rims, an inner rim 3592 and an outer rim 3598 are providedwith a recess 3600 between the parallel rims. A suitably sized pouch3602 can be located into the depression 3596 and the “mouth” 3604 of thepouch can be cuffed over the rim 3592 such that the mouth of the pouchis tensioned around and over the external and upper surface of rim 3592.A vacuum source can be provided to recess 3596, via conduit 3584, suchthat the pouch can be drawn against the internal walls of the depression3596, prior to closing the upper and lower vacuum chambers together. Inthis way the mouth portion of the suitable pouch 3602 can be tensionedacross the rim 3592 in such a manner so as to ensure that no creases arepresent in the pouch mouth section that is located directly adjacent(and above) the rim 3592. Any suitable stretching devices may beprovided that will stretch the mouth section of the pouch and ensurethat no creases are present, thereby allowing subsequent and effectivesealing of the web 3578 to the pouch when required. Following loading ofgoods into the pouch 3602, heat bank member 3572 can be activated so asto provide heating and sealing of a section of web 3578 to the mouth ofthe pouch around the full continuous length of rim 3592. An automaticcutting device 3606, can be arranged so as to provide suitable cuttingand severing of the web 3578 after sealing to the pouch. In this way web3578 can be hermetically sealed to the mouth section of the pouch 3602so as to completely seal and enclose any space and goods that may belocated in the pouch prior to sealing of web 3578 thereto.

Any suitable method of manufacturing a suitable pouch with adequate gasbarrier properties may be employed to manufacture the pouches. Forexample the pouch may include a suitably sized, multi-layer plasticstube, extruded from an annular die with specified layers of materialthat provide all gas barrier and sealing properties and featuresrequired. Such a tube may be extruded and cut into suitable lengths andthen heat sealed to close one end of each length of tube, in anysuitable fashion, to produce pouches and, if required, a valve may befitted to the wall of the pouches. The valve can be arranged to allowexcess gas such as carbon dioxide, that may be generated in the pouchesafter sealing with goods, such as carbonized retail packaged groundmeat, therein.

Referring again to FIG. 149, a grouping of several identical suchmembers 3564 may be arranged by attaching to the upper surface of asuitable conveying device such as a horizontally disposed carouselstyle, circular table, of suitable size arranged with suitable driver tointermittently rotate the carousel. In this way, pouches could beautomatically loaded into each lower vacuum chamber 3566, consecutivelyand immediately prior to loading goods into the pouch. After loading thegoods, the carousel can rotate so as to locate the loaded member 3566directly under upper vacuum chamber 3570 and web unwind assembly so asto allow sealing of a section of web 3578 thereto. In this way, anautomatic and semi-continuous packaging process can be arranged toautomatically open the pouches, load into member 3566, fill the pouchwith goods, evacuate and gas fill the pouch with goods therein and thenheat seal a web of material 3578 over and to the mouth of the pouch. Anautomatic ejection device can be provided that may include a method ofrelaxing tension in the pouch mouth and lifting the sealed and finishedpouch (with goods therein) from member 3566 and then locating thefinished pouch into a carton prior to closing the carton closed andsealing the finished pouch therein.

Referring to FIG. 213, yet another preferred embodiment f an apparatus7200 for producing a master container with finished packages is shown.Equipment 7200 includes an upper chamber 7206 and a lower chamber 7210.A master container 7216 with finished packages 7208 is contained withinlower chamber 7210. The operation of this apparatus is in many respectssimilar to the previous embodiments. Master container 7216 is loadedwith finished packages 7208, and located in the lower vacuum chamber. Aweb 7214 is passed through the chamber to cover the opening in themaster container 7216. The upper 7206 and lower 7210 chambers close,providing a substantially air tight seal. Air is evacuated through anynumber of ports 7204 and 7212. a suitable gas is flushed into thechambers. The cycle can be repeated any number of times to expel the airand/or oxygen from the master container 7216 and packages 7208. Themaster container is then sealed with web 7214. The vacuum chambersseparate, and a new master container is evacuated, flushed and sealed.

In yet another preferred embodiment, the packages need not haveapertures, but rather are sealed or wrapped with a web that expands tofill the voids in the master container to expel the air. This ispossible because the web preferably has memory, to contract to itsrelaxed state. The packages need not be evacuated because packages canbe wrapped in a low oxygen atmosphere according to the invention, thuseliminating the need for values.

Method and Apparatus for Packaging, Labeling and Weighing

Trays containing perishable goods are preferably weighed and labelingprior to sealing. Therefore, it is appropriate to describe a method andapparatus of the invention for such a task.

FIG. 151 shows a packaging machine constructed according to the presentinvention to apply label(s) to the second web and also an alternativeprinting device to print directly onto the second web. Reference is alsomade to patent application PCT/AU93/00484, which is herein incorporatedby reference. FIG. 151 shows a side elevation of the packaging apparatusand FIG. 152 shows a plan view of the upper side of the packagingmachine of FIG. 151. Packaging machine 1800 is arranged in two sectionsto provide a space so as to allow a sufficiently clear area to install ascale 1802 with load cells 1828. Packaging machine 1800 is mounted andattached to the floor (also shown) independently of scale 1802 such thatthey are not in contact with each other. Second web unwind roll 1806 isprovided with braking devices attached thereto. Drive 1804 is arrangedto unwind second web from roll 1806 of second web 1812. Printer 1808 islocated between second web roll 1806 and third web roll. Printer 1808 isattached to driver to move in X, Y and Z axis in horizontal and verticalplanes. Printer 1808 includes a mechanism to print onto labels and thenapply labels to second web or alternatively print directly onto secondweb. Third web roll 1810 is located above second web 1812 and is fittedwith braking devices as well to maintain tautness of the web as it isunrolled. Packaging apparatus 1800 includes a vacuum chamber assembly.The assembly includes a number of components including a lower 1816 andupper 1824 vacuum chamber, a lower 1820 and upper 1822 plate and asealing plate 1818.

FIG. 154 shows a cross-section through the vacuum assembly constructedaccording to the present invention. Sealing plates 1818 are arranged ina conveyor which is driven by a motor as required providing intermittentmovements of the conveyor 1826. Lower vacuum chamber 1816 isindependently moved by pneumatic driver (not shown) so as to applypressure to underside of sealing plate 1818. Plate 1820 is locatedbetween sealing plate 1810 and plate 1822. Plate 1822 has vacuum port1830 provided therein. Upper vacuum chamber 1824 is located above plate1822. All components are in vertical alignment and when lower chamber1816 and upper chamber 1824 are retracted and moved in the verticalplane away from each other, plates 1818, 1820 and 1822 which can bespring loaded also “expand” away from each other so as to allow freemovement of first 1836 and second 1832 webs between plate 1820 and plate1827 or between plate 1818 and plate 1820 as may be selected accordingto requirements or preferred operation of apparatus. As is shown in FIG.154, third web 1834 enters the vacuum chamber assembly between plates1822 and 1824 and exits the vacuum chamber assembly between plates 1820and 1822. Also it can be seen that second web 1832 enters vacuum chamberassembly between plates 1820 and 1822. A space 1838 is shown between thesecond 1832 and third 1834 webs with port 1830 opening into space 1838.During the operation of the packaging apparatus, after closing of lowervacuum chamber 1816 and upper vacuum chamber toward each other therebyproviding a closed and sealed vacuum chamber, a vacuum source can beapplied to port 1830 and thereby evacuate substantially all air from thespace 1838. Evacuation of air from space 1838 can cause second 1832 andthird 1834 webs to become laminated together after removingsubstantially all air from the space 1838. Slots shown as 1840 areprovided between the faces of plates 1816 and 1818, 1818 and 1820, 1820and 1822, and 1822 and 1824. These slots provide spaces between each ofthe components also, “O” rings are fitted along the outer edges of eachslot to provide a seal when the components are in contact with eachadjacent component. A vacuum source can be applied to each of thesespaces, simultaneously, thereby providing a method to hold them togetherwith a force equal to that provided by the ambient atmospheric airpressure prevailing at the time. The holding force that urges thecomponents together is therefore approximately equal to the width of theslots between each component, times the length of the slot, multipliedthe difference of the prevailing atmospheric air pressure minus the airpressure within the slots defined by the equation:F=WL(P _(a) −P _(s))wherein,

F is the force,

W is the width of the slot,

L is the length of the slot,

P_(a) is the atmospheric pressure, and

P_(s) is the pressure inside the slot.

The width of each slot can be arranged, by enlarging (or decreasing) soas to provide a level of force that exceeds the desired and opposingforce of gas pressure within the closed chamber. A pair of “O” rings arealso provided around all shafts that penetrate the chamber and spacesprovided between each pair of “O” rings can also be evacuated.

Referring again to FIG. 151, printer 1808 is equipped so as to eitherapply a label or print desired information onto second web 1812. Loadcells 1828 are located along a beam 1854 that extends across and underthe full width of sealing plates 1818. Beam 1854 can be elevated andlowered. Scale 1802 and beam 1854 is arranged to elevate load cells 1828upwardly so as to contact underside of trays in apertures of sealingplates 1818 and lift the trays from apertures in sealing plates 1818 inconveyor. Trays are lifted to an extent that prevents any contact withanything else apart from the load cells 1828. The weight of eachseparate tray can thereby be determined and this information istransferred to a printer 1808. Printer 1808 prints information ontolabels (prior to application of label onto second web) or directly ontothe second web 1812. Second 1812 and third web 1856 are then laminatedtogether before heat sealing to flanges of first web trays.

FIG. 153 shows one embodiment of a single register detail of second web.The single register detail includes a frame 1842 of heat activatedadhesive that can be printed directly onto web. The frame is arrangedwith dimensions that correspond to the flange of third web tray suchthat the frame 1842 covers flanges and located above third web tray.Other details of package contents are also shown and boxes 1846 provideareas onto which information can be printed at the time of packaging.Barcode 1847 contains product information, such as date of packaging andweight, which can later be used to determine price at the point of sale.

FIG. 155 shows a cross-section view through a laminating assemblyincluding a first 1848 and second 1850 driven rubber coated rollerarranged in horizontal disposition and with devices (not shown) to beurged toward each other so as to press and laminate the second 1832 andthird 1834 webs when the webs are passed between the rollers. Rollersare driven by a variable speed motor (not shown). Laminating assemblycan be located between the third web roll 1810 and the vacuum chamberassembly and provide a method to laminate second 1832 and third 1834webs together before entering the vacuum chamber assembly.

Method and Apparatus for Packaging Trays

Trays with flaps constructed according to the present invention can besealed by a first and second web. Webs are sealed to the flap in thenon-folded state in two or one heat sealing stations. Upon bending ofthe flaps, the webs are stretched, thus, providing a taut appearance andprotection for the perishable goods inside.

The following description provides apparatus and methods for productionof a package of the type shown in FIG. 158, with a pre-stretched secondweb 1004. The preferred use of this embodiment is for the packaging ofshallow products such as boneless pork loin chops, butterfly steaks,thick-cut bone in pork chops and New York Strip, super trim beef andpork cuts that are generally not displayed in the package by shinglingbut are laid flat and adjacent to each other and spaced apart so that aconsumer can inspect carefully.

FIG. 168 shows a sketch of a side elevation of a preferred packagingmachine constructed according to the present invention that can be usedto produce packages of types described herein in this disclosure. Thepackaging machine includes a frame supporting a driven conveyor with tworoller chains located one on each side the packaging machine and engagedwith a first 1044 and second 1128 set of sprockets, each pair of thesprockets is located at opposite ends of the frame. Sealing plates,1012, as shown in FIGS. 159-162 are attached to the roller chains viaattachment points. First and second stations, generally denoted by 1014and 1016, respectively, are located on the upper side of the packagingmachine with web unwind arrangements rolls 1130 and 1132 and scrap webwind-up arrangements at 1120 and 1138. Continuous conveyor 1010 carriessealing plates 1012 in the direction indicated by arrow 1126. Details ofa preferred sealing plate 1012 can be seen in FIGS. 159-162. Preferably,first and second stations 1014 and station 1016 are mounted onto theupper side of the packaging machine frame adjacent to the upper sectionof the conveyor 1010. A loading section 1018 is preferably locatedadjacent to and down stream of station 1014. Conveyor 1010 is supportedwithin the frame and is attached to a powered indexing device for movingthe conveyor 1010 and sealing plates 1012, intermittently and in adirection from loading section 1018 toward first station 1014.Preferably, each intermittent movement of conveyor 1010 travels onepitch which is equal to at least the distance required to move a sealingplate 1012 the full distance of the length of the sealing plate.Preferably, with each movement of the conveyor, a sealing plate islocated directly between the lower vacuum chamber 1020 and the lowerclamp plate 1022 shown in FIG. 167. Preferably, a sealing plate is alsolocated directly beneath heat bank 1024, as shown in FIG. 156.Preferably, this arrangement transfers a package that has been sealed infirst station 1014, to a subsequent location at second station 1016.Preferably, the driving devices for the packaging machine, machinecomponents and conveyor are a pneumatic cylinder and electricallypowered driving motors of suitable size and capacity. The pneumaticcylinders are attached to shafts 1030 (attached to heat bank 1024), 1032and 1028 (attached to water-coded clamp 1036) and, 1034 and 1026(attached to cutting device 1038), and provide independent reciprocatingmovements to each shaft and attachments generally in the directionsshown in the diagrams by arrows drawn adjacent to each attachment.Similarly, pneumatic cylinders (not shown) are attached to upper 1056and lower 1020 chambers to provide reciprocating movements parallel withshafts 1030, 1028, 1032, 1026, and 1034 to provide movement and applypressure as required. Preferably, an electrically powered drive motor1042 is attached to conveyor sprocket 1044 so as to intermittently drivethe conveyor 1010 as required such that the upper section 1046 of theconveyor travels in a direction from right to left.

First Heat Sealing and Vacuum Chamber

FIG. 167 shows a cross-sectional view through a first station vacuumchamber assembly 1014 constructed according to the present inventionwhich details the first 1002, second 1004 and third 1006 webs prior tosealing the webs together. This vacuum chamber has a plate, separatingto second and third webs, unlike the chamber of FIG. 154. Meat is loadedinto tray (first web 1002) and then each loaded tray is placed intoapertures in sealing plate 1050. The conveyor indexes forward such thata loaded tray is located at first station 1014. During indexing, thirdweb 1006 and second web 1004 are also indexed forward and alongitudinally disposed tension can be applied to third and second websand in a direction parallel with the conveyor. Preferably, lateralstretching can also be applied to second web 1004 such that it isstretched taut. Upper clamp member 1052 and lower clamp member 1022 thenclose against the middle clamping plate 1054 thereby clamping and firmlyholding third and second webs 1006 and 1004, respectively. Preferably,lower vacuum chamber 1020 and upper vacuum chamber 1056 are closedagainst the clamping plate assembly such that a substantially “airtight”seal is provided and the upward movement of lower vacuum chamber 1020lifts sealing plate 1050 and holds it firmly against the underside ofthe lower clamp 1022 thereby providing substantially “airtight” sealsaround the perimeter of the upper and lower vacuum chambers 1056 and1020. Closing the upper and lower chambers thereby defines a singleenclosed chamber that is substantially isolated from atmospheric gasses.During the procedure of closing the upper and lower chambers, the lowervacuum chamber 1020 lifts the sealing plate 1050 upwardly and tray(first web 1002) is carried upward. The upper rim portion of sealingplate 1050 and 1058 contacts the underside of second web 1004 stretchingsecond web upwardly until sealing plate 1050 contacts the underside oflower clamp 1022 at surface thereby stopping the upward movement in aclosed and substantially “airtight” condition. Preferably, the secondweb 1004 is now stretched taut across the opening of the ring 1058 anddistanced preferably about 1/64″ to about ½, and most preferably about⅛″ above flange 1072 (FIG. 158) and preferably about 1/64″ to about ½,and most preferably about ⅛″ below third web 1006.

Preferably, atmospheric air contained within the enclosed chamber isthen substantially evacuated through evacuation ports 1008, to apressure of less than 5 torr. Preferably, immediately after evacuation,the chamber can be filled with carbon dioxide gas, or a blend of carbondioxide and nitrogen gasses, to a pressure of up to 2 bar (28 psi) ormore, by injection through ports 1064 and optionally 1008, and held atpressure for a period of 1 to 5 seconds or more and most preferablyuntil water and goods in the tray have become substantially saturatedwith dissolved carbon dioxide. The gas pressure within the chamberassembly can then be lowered to a pressure equal to that of theprevailing ambient atmospheric pressure prior to sealing. Evacuation andgassing of the chamber assembly in accordance with the invention,provides a method of filling packages with a chosen gas such that theresidual atmospheric oxygen that remains within the package does notexceed an amount about 0.05% by volume of the gas that remains withinthe package after sealing the first 1002, second 1004, and third 1006webs together.

Referring now to FIG. 158, a clamping member 1036, that is preferablywater cooled, can now be moved and positioned so as to clamp third web1006 against second web 1004 and in turn against the inner edge portionof flange 1072 on first web tray 1002. Preferably, heat bank 1024 canthen clamp and heat seal second and third webs 1004 and 1006 to flangeof first web 1002, under pressure. Preferably, heat bank 1024 can now beretracted followed by cutting of second and third webs with cuttingmember 1040 attached to cutting device 1038. The cutting member iswithdrawn from the cutting position followed by release of clamp 1036.Preferably, enclosed vacuum chamber assembly can then be opened allowingconveyor to move forward a single pitch followed by closing the enclosedchamber assembly, followed by evacuation, gassing and heat sealing.Preferably, this cycle can be repeated in an automatic and continuousmode. Vacuum chamber assembly constructed according to the presentinvention and frame to which it is attached is built in a manner thatwill allow continued cycling of the packaging process and pressurizationwithout sustaining excessive damage other than normal wear and tear.

An optional method of using the apparatus whereby a gas is not providedin the space between third web 1006, the upper barrier web, and secondweb 1004 (so as to subsequently facilitate urging of the second 1004 andthird 1006 webs together), before sealing the third web 1006, second web1004 and first web 1002 (shown as tray) together at a path near whatwill be a perimeter of the package. The tray 1002 is elevated so as tourge second web 1004 toward the underside of third web 1006 therebyproviding stretching means to second web 1004 to sealing webs togetherto form a package. Apparatus for evacuation of substantially all airfrom the space between the third 1004 and the second 1004 webs, throughports 1008 is optionally provided.

Preferably, packages are then transferred from the vacuum chamber atfirst station 1014 via the conveyor to the secondary sealing apparatuslocated at second station 1016.

Second Heat Sealing Chamber

Referring now to FIG. 156, a cross-sectional view of second station1016, constructed according to the present invention is shown in apartially closed position.

Referring to FIGS. 157-158 a cross-sectional view through a finished andsealed package constructed by second station 1016 is shown. Package 1092includes a flange with second web 1004 and third web 1006 attachedthereto. Shown is first web, tray 1002, formed with two flange portions1072 and 1074. Preferably, flange portions 1072 and 1074 are adjacentand concentric to each other, with flange 1074 located on the inner sideof flange 1072.

Referring now to FIG. 156, an assembled package is positioned in thesealing plate which is located beneath heat bank 1070. It can be seenthat lip 1080 has a profile that corresponds and follows the path andplan profile of flange portion 1074. A section of flange 1074 can beclearly seen in the enlarged cross-section in FIG. 157. Preferably,flange portion 1074 is parallel and concentric to flange portion 1072but follows a path on the inner side of flange portion 1072 and at aplane shown to be at a distance 1076, about ⅛″, below flange portion1072. Preferably, heat bank 1070 is pneumatically operated and canextend downwardly and be retracted upwardly as required to exert a forcesuch as to provide pressure onto the lip 1080 and when engaged withflange portion 1074, simultaneously depressing third and second websthat are then held, under pressure (sealing pressure), between thesurface of flange portion 1074 and lip 1080 for a set period of time(set time). Preferably, the temperature of heat bank 1070, andcorrespondingly lip 1080, can be controlled and is set at a suitabletemperature (set temperature). Preferably, the temperature of heat bank1070 is less than temperature of heat bank 1024 located in first station1014. Preferably, pressure is applied at lip 1080 and can be set atsealing pressure. The suitable time of contact and clamping of third andsecond webs to flange portion 1074 can be varied. Time of contact isdefined as the length of time during each cycle from the first instantof first contacting between lip 1080 and flange portion 1074 through thethird and second webs, to the first instant of no contacting afterretraction of heat bank 1070. Thereby, when the set temperature, sealingpressure and set time of heat bank 1070 are adjusted as required, theselective heat sealing of second web to flange portion 1074 can beachieved while third web does not heat seal to second web. This canpreferably be achieved when first, second and third webs includematerials as shown in FIGS. 43 and 44.

Referring now to FIGS. 43 and 44 a representation of an enlarged view ofa section through a flange portion of an assembled package is shown.FIG. 43 shows heat sealing bars and a section of a rubber seal mountedon sealing plates around the perimeter of the apertures in the sealingplates. Details of materials that can be used in the first, second andthird webs are also shown and described in detail below: Preferably,third web 1006 is a co-extruded web including at least two layers with afirst layer 1082 of Eastman PET 9921 and a second layer 1084 of materialon the underside of the third web including a blend of 2 grades ofEastman polyesters in amounts of about 50% Eastobond 6763 and about 50%Eastobond 9921 or alternatively the layer on the underside may be about100% Eastman PM 15086. Preferably, third web can be about 0.006″ thick,about equally divided between first and second layer. Preferably, secondweb 1004 is a web of pPVC with a thickness of about 0.0008″. Preferably,first web 1002 includes a thermoformed tray produced from a multilayerco-extruded web with an outer layer 1088 of Eastman 9921 and an innerlayer 1086 including a blend of about 50% Eastman PETG 6763 and about50% Eastman 5116 (or Eastman PM14458 or equivalent). Preferably, firstweb has a thickness of about 0.012″ where the inner layer 1086 is about0.004″ thick and the outer layer 1088 is about 0.008″ thick. Preferably,under such conditions the heat transferred through third web isinsufficient to cause bonding between the third and second webs butsufficient to cause bonding between the second and first webs at flangeportion 1074. Preferably, such arrangement provides stretching of secondweb, after sealing of third and second webs to first web at firststation 1014. Preferably, applying gas pressure to the upper surface ofthe third web, when located at second station 1016, so as to cause thesecond and third webs to depress downwardly and substantially conform tothe contours of flange portion 1074 prior to providing heat seal 1090provides an alternative step in the method.

Preferably, second web 1004, will have a feature known as a “memory”.The term “memory”, in this context, is known in the packaging industryand is characterized as a material that will substantially return to itsoriginal shape after distortion has occurred due to, for example, aconsumer “feeling” the goods contained within the package while thepackage remains intact, with second web sealed to the tray flanges. Thiscan cause finger marks and depressions in the second web as prospectivepurchasers of the package examine it prior to purchase during retaildisplay of the package. After excessive handling by consumers thepackage can become unattractive to an intending purchaser and financiallosses can result therefrom. Materials such as polyethylenesubstantially do not have “memory”. However, plasticized PVC (pPVC) webmaterials, such as are made by Borden do provide this important feature.Second web constructed from pPVC may be perforated by perforatingapparatus to improve gas transmission therethrough.

Preferably, perforations can be provided in second web 1004. Theperforations can allow gas to permeate into a space between second weband third web. Preferably, when the gas pressure inside the sealedpackage is at a pressure slightly above ambient air pressure, third webwill be stretched outwardly into a dome shaped condition therebyproviding a gas buffer between third web and the surface of goodsbeneath the second web. Second web may be in contact with the surface ofpackage goods, alternatively a space can be provided therebetween.Preferably, the seal between second web and first web may be arrangedsuch that it is not a continuous seal along the full path of flangeportion 1074 and may be arranged as an intermittent sealing, completelyalong one or more sides only or parts thereof.

In yet another embodiment heat bank 1070 may be mounted at first station1014, concentrically with and on the inside of heat bank 1024 within thesame chamber but with separate moving shafts. Such an embodiment wouldallow sealing at flange portion 1072 and flange portion 1074 without theneed to transfer the package from first station 1014 to second station1016 for sealing of flange portion 1074. Preferably, web cutting devicesare located at second station 1016 to separate the sealed and finishedpackage 1092 from webs.

After passing through stations 1014 and 1016 on packaging machine, thefinished packages are ejected from the machine.

In yet a further embodiment, the tray evacuation arrangement can be setup to transfer trays containing goods to a vacuum chamber, evacuate anyambient atmosphere from the trays and then transfer the trays into anenclosure excluding air. However, the trays have not been sealed with alid at the vacuum chamber.

Sealing Plates

Sealing plates constructed according to the present invention aremembers attached to conveyors to carry trays in the packaging system.

FIGS. 163-166 show the use of sealing plates with trays of the presentinvention. Package 1224 contains goods 1214 shown in FIG. 163. In FIG.163, the first web 1200, second web 1202, and the third web 1204 areshown sealed together to form a complete package 1224. FIG. 164 shows across-section through the tray (the first web). Dotted lines are shownin FIGS. 164-166. The dotted lines in FIGS. 164-166 show the position ofthe side walls before insertion of the tray into the aperture 1206 inthe sealing plate member 1208. Dotted lines in FIG. 166 show therelative position of the edge of the flange prior to the tray insertioninto the aperture. The aperture is sized to suit and is slightly smallerthan the tray. The aperture is located in member 1208 which includes aplate means with the aperture therein with the aperture havingdimensions slightly smaller than the external dimensions of the sidewalls of the third web tray such that when the tray is inserted into theaperture, the side walls are distorted and urged inwardly. The solidlines show the side walls after the inward distortion and the dottedlines show the relative position of the tray prior to insertion into theaperture. FIG. 164 shows a plan view of a section of a conveyor such asmay be installed in a packaging machine. Sealing plate 1208 may have aplurality of apertures, all of a suitable size and arranged to hold aplurality of the trays in like distorted condition as herein described.

Referring to FIGS. 159-162, a cross-section of a preferred sealing plate1050 constructed according to the present invention is shown with a planview shown in FIG. 160. Sealing plate includes attachment points 1094.Preferably, attachment points 1094 attach the sealing plates to a pairof continuous roller chains that engage with sprockets 1044 and 1128 andare located, one at each relative side of conveyor. Preferably, sealingplate 1050 has a depth dimension that is about equal to or deeper thanthe depth of depressions in first web. Preferably, a rubber seal 1100 isattached to the sealing plate 1050 by an adhesive and is profiled toprovide flanges 1096 and 1098 that correspond to flange portion 1072 andflange portion 1074 of first web tray. Preferably, a space between therubber seal 1100 and rim 1078 is provided to allow clearance for cuttingmember 1040 during the cutting of the third and second webs aftersealing to flange portions 1072 and 1074.

Referring now to FIG. 162, a cross-sectional view of the details ofsealing plate 1050 are provided. As an example, a preferred embodimentwith three apertures 1150 and rubber seals 1100 located around theperimeter of each aperture is shown. However, sealing plates may havemore or less apertures and corresponding rubber seals. Preferably,rubber seals are made optional. Preferably, sealing plates are machinedfrom aluminum or other metals or any suitable plastic plate, forexample, about 0.75″ thick polypropylene with upper 1152 and lower 1154faces.

Referring again to FIG. 164, wherein the arrangement of first web 1200(tray) with a flange 1210 extending continuously around the perimeter oftray 1200 to provide a flat ledge to which second web 1202 is sealed.Preferably, tray 1200 has been distorted such that side walls are urgedinwardly and held in position by the limiting size of aperture 1206located in sealing plate 1208 of FIG. 165. Preferably, second web 1202is a gas permeable material such as pPVC of about 0.0008 inchesthickness and first web 1200 is constructed of a substantially gasimpermeable material such as a co-extruded multilayer sheet of EastobondAPET 9921 and a blend of about 16% Eastobond PETG 6763 and about 84%Eastobond 9921. A third web 1204 is sealed to second web 1202 adjacentto seal 1212 of the second web to the first web.

Alternatively, the tray 1200 can be formed from a web of polystyrenefoam that has been previously laminated to a web of gas barriermaterial. A second web of material can be sealed to the web of gasimpermeable material laminated to the upper side (inside) of foam tray.Trays according to the present invention are substantially impermeableto gases.

Referring to FIG. 163, webs are shown sealed together by a strip-likeseal 1212 on flange 1210 that follows a path that continues around theflange near the perimeter of the package thereby providing asubstantially hermetically sealed package. Preferably, goods 1214 arecontained within the sealed package and a suitable gas blend such as mayinclude about 40% carbon dioxide and about 60% nitrogen is providedwithin the package. Preferably, sealing of the package is effected whileside walls of the tray are urged inwardly. Preferably, side wallsthereby retain a tension and desire to return to their original relativeposition thereby exerting a substantially outwardly disposed urgingaround the perimeter of the depression in the tray but which is retainedand held captive by the combined tensile strength of third and secondwebs sealed to the flange. Preferably, third web is sealed to thepackage in such a manner as to allow peeling from the package, withoutrupturing second web and thereby leaving second web attached to theflange. Preferably, when third web is peeled from the package thetensile strength of the second web is insufficient to restrain outwardlyurging of the side walls, thereby releasing urging and providing a meansto stretch the second web into a substantially flat condition. Theextent of the urging can be controlled such that it will maintain atension in second web.

FIG. 163 shows a finished package that has been produced by the methodherein described and, after heat sealing of first 1200 and second 1202webs together, has been removed from aperture 1206 in sealing plate1208.

Method and Apparatus for Producing Laminated Webs

Having discussed the advantage obtained by packaging trays having secondand third webs, another embodiment of producing bilayer coverings isherein described. Referring to FIG. 169, an apparatus for producing apre-stretched second web of flexible gas permeable material laminated toa substantially more rigid gas barrier material is schematicallyillustrated.

First 1400 and second 1402 roll of web material including a second web1404 and a third web 1406 are preferably unwound simultaneously andlaminated by passing the webs through a pair of “nip” rollers 1408 thatapply pressure against each other and to the webs as they pass throughnip rollers 1408. Preferably, nip rollers 1408 are driven by anysuitably powered driver to rotate at a suitable speed. Preferably, thelaminated web 1412 is rewound onto a single roll 1410 together toproduce a laminated web 1412. Third web 1406 may include a semi rigidpolyester material, of about 0.005″ to about 0.007″ thick. Theconstruction of this material is such that it can be used in a packagingmachine to produce packages as described herein whereby laminated websare sealed to a first web of gas barrier material (tray). First web mayhave a depression formed therein into which goods such as red meat canbe placed before heat sealing the third and second webs to the firstweb. Goods will typically not completely fill the depression and spacewill remain in the depression in addition to the goods. A blend of gasesor a single gas such as CO₂ can be provided in the space with goods andthereby can contact the goods. The gas substantially eliminates thepresence of oxygen and any red color present in the red meat may betransformed to a purple color. This is caused in part by the reductionof oxymyoglobin to deoxymyoglobin. After storage of perhaps a period of14-28 days from packaging but prior to retail display at an intendedpoint of sale to consumers, the third web can be peeled from the packageallowing atmospheric oxygen to permeate the second web of gas permeablematerial and to contact the goods. Atmospheric oxygen can then generatea bright red colored substance such as oxymyoglobin. Such use involvesthe sealing of the laminated webs to the first web of gas barriermaterial such as a two-layer co-extrusion where the outer layer includesEastman APET 9921 of about 0.0035″ thickness, and the inner layer may isa blend of Eastman polyester materials including about 16% of 6763 andabout 84% of 9921. The thickness of blended layer 1412 can be about0.0015″. Second web 1404 includes a roll of monolayer pPVC with athickness of about 0.0008″ to about 0.0012″. Preferably, as second web1404 is unwound it can be passed through a perforator 1414 thatperforates the second web by creating small apertures therethrough.Preferably, second web 1404 can be tensioned in a controlled manner byretarding the rate of unwinding of second web 1404 from roll 1400relative to the unwinding rate of third web 1406 from roll 1402. Tensionis thereby applied to second web 1404 of material prior to passingthrough the nip rollers 1408 at which point substantially all of the airbetween the two layers of material is forced out by the nip rollers1408. The consistency and texture of elasticized PVC material includingsecond web 1404 is such that it adheres lightly to third web 1406unwound from roll 1402 forming a very light seal that excludes all airfrom between the webs. Second web 1404 is applied to the inner, blendedlayer of third web 1406, preferably a substantially more rigid materialunwound from roll 1402. Preferably, an anti-blocking agent, such as veryfine sand, can be added to the third web upper (outer) layer of theco-extrusion so as to preferentially inhibit sticking of second web towhat will be upper layer such that second web will remain in closecontact with what will be the underside of third web during storage in aroll 1410 condition and during unwinding from roll 1410 in normaloperation on a packaging machine.

Second 1404 and third 1406 webs, having been laminated to produce alamination and subsequently wound onto the finished roll 1410 can bestored and when required for use in packaging can be loaded ontopackaging machine as shown in FIG. 170.

Referring now to FIG. 170, a process to laminate two webs of materialtogether is shown. The two webs include the third and second webs. Theapparatus is suited to produce any packages herein described. First web1416, preferably of a substantially gas barrier material is located intoan aperture (not shown) in sealing plate 1418 mounted on the conveyor1420. Preferably, sealing plate 1418 being similar to sealing platemember 1208 shown in FIG. 159. Preferably, first web has a cup-shapeddepression formed therein and similar to that shown in FIG. 171. Redmeat or other perishable goods is loaded into first web tray 1416 and aplurality of trays are located into the apertures in each sealing plate1418 mounted to conveyor 1420. The conveyor indexes forward such that aloaded tray is located between upper vacuum chamber 1422 and lowervacuum chamber 1424. During indexing of the conveyor the third web trayis also indexed in a direction parallel with the conveyor and placedinto position between upper and lower vacuum chambers. Upper 1422 andlower 1424 vacuum chambers are closed together such that sealing plateis clamped therebetween to provide a substantially sealed and enclosedchamber assembly. Air is evacuated from the chamber assembly to apressure level of approximately 5 torr and a selected gas is injectedinto the chamber assembly. The gas being chosen for its properties ofenhancing the keeping qualities of goods, in first web tray 1416, suchas carbon dioxide or a blend of carbon dioxide and nitrogen is suitable.First, second and third webs are then sealed together to produce apackage. Upper 1422 and lower 1424 vacuum chambers are then opened sothat conveyor 1420 can carry sealed package to an ejection point. Thepackage may be trimmed by a cutting devices located within the chamberassembly such that a skeletal scrap web can then be wound onto a singlewind-up spool, or alternatively, could be separated by de-laminating thethird web scrap from second web scrap onto scrap wind-up 1426 and 1428as shown in FIG. 48. The package may be trimmed within vacuum chamber inone machine cycle or alternatively the package may be trimmed from theweb in a secondary operation immediately after the vacuum chamber.

Preferably tray construction may be thermoformed from co-extrudedpolyester plastic materials as shown in FIG. 171. Co-extruded materialmay include two layers of a total thickness of about 0.015″. The outerlayer 1430 is about 0.0135″ thick and the inner layer 1432 is about0.0015″ thick. The outer layer 1430 includes Eastman APET 9921 and theinner layer 1432 is about a 50%/50% blend of Eastman 13162 and Eastman6763.

Method and Apparatus for Packaging Perishable Goods

Having described laminated webs, it is now appropriate to describe amethod to package perishable goods using a laminated web. Although thedescription preferably applies to laminated webs, one or morenon-laminated webs can also be used with the method with apparentmodification.

FIG. 172 shows a schematic representation of a side elevation of apreferred packaging apparatus including a conveyor with a plurality ofsealing plates generally denoted 1436 attached thereto. Preferably, adrive motor 1438 is connected to conveyor sprockets 1440 a, and b andarranged so as to provide intermittent driving of the conveyor asrequired. Trays with goods therein are loaded into apertures in sealingplates at the loading section and the conveyor is driven forward in theconveyor direction shown in intermittent increments of one pitch whichis equal to the distance of a single sealing plate. The conveyor isotherwise stationary except during each movement of one pitch. A scale1442 can be positioned under the upper section of the conveyor and isattached to a driver such that when the conveyor is stationery the scalecan be elevated and lift the tray from sealing plate 1436, and weigh thetray and goods. Preferably, scale can be interfaced with a labelprinting device. Preferably label will include information such asprice, weight and time of packaging and then label printing device willapply the label to the upper surface of the second (or third web) in alabel position. Label position can be predetermined such that whenfirst, second and third webs are sealed together the self adhesive labelis in a desired location which can be easily seen by any prospectivepurchaser of the finished package after removal of the third web.Alternatively, if the label is located on the third web and if the thirdweb is not removed before retail display then the label can be viewed. Aroll of material 1444 is mounted above the conveyor adjacent to a firststation 1446 to facilitate unwinding of the material 1443. The materialmay include a single web of material or alternatively the material mayinclude a roll of two laminated webs such as described above. Packagesproduced with material according to the present invention would besimilar to packages shown in FIG. 173, whereas packages produced withweb conventional material would be similar to the conventional packagein FIG. 174. First station 1446 includes an upper vacuum chamber 1448and lower vacuum chamber 1450 and both are mounted to the packagingmachine and pneumatic drivers. Pneumatic drivers are arranged to movethe upper 1448 and lower 1450 vacuum chamber in a reciprocating upwardand downward motion.

Preferably, vacuum chambers operate such that they move simultaneouslybut in opposing directions such that when they are moved toward eachother a sealing plate 1436 is clamped therebetween to provide acompletely enclosed chamber that is isolated from ambient atmosphere.Preferably, each vacuum chamber has ports 1452 and is attached to avacuum pump (not shown) and sources of gases via ports 1452. Preferably,the gas sources can be several in number but typically can include: 100%carbon dioxide and a blend of carbon dioxide and nitrogen in anyconcentration. Sources of gas can be switched from one to the other suchthat a selected gas can be injected into the chamber as required and atwill. For example after evacuation of the vacuum chambers, a gas, suchas 100% carbon dioxide, can be provided in the vacuum chamber at a gaspressure above ambient atmospheric pressure, for example about 25 psi.Gas pressure may then be reduced to any pressure between about 0 andabout 25 psi before then providing a gas, such as 100% nitrogen, in thevacuum chambers. A heat bank sealer 1454 is located within the uppervacuum chamber 1448. Sealing device is also attached to a pneumaticcylinder that provides motion in an upward and downward fashion. Sealingdevice is profiled to provide a flat strip like surface, horizontallydisposed, that corresponds to the flange of the tray and can applypressure downwardly onto the flange. Preferably, second station 1456includes lower clamp 1458 and upper clamp 1460. Preferably, clamps 1485and 1460 are attached to pneumatic cylinder and can be operated suchthat when moved toward each other a single sealing plate 1436 is clampedtherebetween. Preferably, a sealing device is located within the upperclamp 1460 with pneumatic cylinders attached thereto and a cuttingdevice 1462 is located on the outer perimeter of heat bank 1464 and onthe inside of 1460. Preferably, members 1462, 1460, 1464, and 1458 canbe moved independently and in vertical directions. A winding arrangement1466 is mounted above the conveyor and is powered by an electric driverto wind skeletal scrap. The preferred sequence of operation of thepackaging machine is as follows. Sealing plate 1436, attached to theconveyor with a loaded tray contained therein is indexed into positionin first station 1446. Lid material 1443 is unwound from 1444 andlocated above tray 1436. Chambers 1450 and 1448 are clamped togetherwith 1436 clamped therebetween. Air is substantially evacuated from thevacuum chambers which are then filled with carbon dioxide gas or a blendof carbon dioxide and nitrogen. The gases are pressurized to a pressureabove atmospheric pressure to about 25 psi and held for a periodexceeding about one second. Pressure of the gas in the chambers isreduced to about atmospheric pressure and sealer 1454 is lowered so asto clamp the lid material against the flange portion of the tray. Thelid material is then sealed thereto along the complete path of trayflange. Vacuum chambers 1448 and 1450 open and the conveyor indexesforward until sealing plate 1436 is located at second station 1468,between upper clamp 1464 and lower clamp 1458. Clamps 1464 and 1458close together thereby clamping sealing plate 1436 between the clamps.Sealing device 1464 is lowered to seal the lid material to tray atflange and cutting device 1462 is also lowered and retracted therebysevering the tray and package from web while the tray still located inthe sealing plate 1436. Skeletal scrap is wound onto scrap winding spool1466. Conveyor indexes forward and packages are ejected therefrom.

Cross-sections through the package shown in FIG. 173 and a conventionalpack of FIG. 174 are shown alongside for comparison. The conventionalpackage shows the absence of second web. The tray constructed accordingto the present invention include a second and third web sealed to a trayflange around the upper periphery of the tray. A tray constructedaccording to the present invention provides a peelable lib to introduceoxygen at a predetermined time, thus extending the shelf life of theperishable good stored therein.

Method and Apparatus for Packaging Finished Packages

Now that trays, webs, and methods have been described, it is appropriateto consider master packs and their methods for making.

Referring now to FIG. 175, details of a packaging apparatus constructedaccording to the present invention for producing substantially gasbarrier master containers and heat sealing a substantially gas barrierlid material to the master containers to produce hermetically sealedcontainers is shown. The following description discloses a method andapparatus for producing the hermetically sealed containers for providinga vacuum and/or selected gases in the containers at selected andvariable pressures, so as to accelerate the dissolving of selectedgasses into perishable goods such as red meat that may be containedtherein and then exchanging the selected free gases with other suitablegases for the purpose of enhancing the keeping qualities of theperishable goods. Furthermore, the method provides methods of removingresidual oxygen gas that may be retained within the cell structure ofpackaging materials such as EPS, that may be contained in thehermetically sealed master.

FIG. 176 shows a cross-section through an apparatus intended to producemaster packs thermoformed from a continuous web of plastics material.The dimensions of the master containers are arranged so that they can befilled with preferably an exact number of finished packages containingperishable goods such as any of the finished packages herein described.The apparatus preferably includes a horizontal thermoforming, reel fedpacking machine, similar to Model R530 packing machine manufactured byMultivac Sepp Haggenmuller GmbH & Co. of Germany.

Preferably, the apparatus includes a frame (not shown) that is arrangedwith two horizontally disposed and parallel continuous gripper chainsgenerally denoted as 4400 in FIGS. 176, 177 and 178 that run almost thefull length of the frame and are retained in tracks that are located oneach side of the frame. Gripper chains 4400 are arranged to grip the twoopposing edges of the lower web 4402 and apply suitable lateral andlongitudinal tension thereto. The machine direction is shown by arrow4444 and the chain is preferably powered by an electrical motor (notshown) that is controlled electronically to carry the lower web 4402 inthe machine direction in intermittent movements. The distance traveledby the gripper chains, carrying the lower web, is controlled so as tocarry the formed master packs 4402 forward and simultaneously locate asuitable area of the lower web material 4402 between the upper and lowersections of the thermoforming section. Each intermittent movement,during each machine cycle, of the gripper chains is equal in distancetraveled and the apparatus can be arranged to automatically operate at amachine speed of a set number of cycles per minute which may be,preferably about 4 cycles per minute.

During a single machine cycle the following functions preferably occur.After the gripper chains cycle forward carrying a section of lower webmaterial 4402 into position between the upper and lower sections of thethermoforming section 4406 the upper and lower sections close togetherand thermoform master packs including, in the present case, threecontainers. A hole punch 4466 is arranged to provide apertures 4452 inthe lower web located between the containers as shown in FIG. 176 and inan enlarged cross-sectional view in FIG. 178. Finished packages are thenloaded into the master packs (containers) in the loading section 4446and with each machine cycle the lower web travels forward an equaldistance. The gripper chain carries the lower web 4402 in the machinedirection a distance of a single pitch for each machine cycle until theloaded master packs are located between upper chambers, generallydenoted by 4410 and lower chambers, generally denoted by 4412.Preferably, a total of five upper chambers and five corresponding lowerchambers are arranged such that the upper chambers 4414, 4416, 4418,4420 and 4422 can be elevated and lowered as required. Lower chambers4424, 4426, 4428, 4430 and 4432, are located directly below the upperchambers and arranged with powered drivers (not shown) to elevate andlower the lower chambers as required. A cross-section is shown in FIG.176 and is typical for upper chambers 4414, 4416, 4418, and 4420 withcorresponding lower chambers 4424, 4426, 4428, and 4430. Upper chamberassembly 4410 and the lower chamber assembly 4412 operate simultaneouslyso as to close toward each other and open away from each other, asrequired. During a single machine cycle upper chambers and lowerchambers close and open once. After upper chambers and lower chambersopen, gripper chains 4400 carrying the lower web 4402 move and carry themaster packs forward for one single pitch. A roll 4434 of upper webmaterial is located as shown and upper web material 4444 is unwound, asrequired, during each machine cycle, providing a length of upper webmaterial equal to the distance of the lower web forward movement. A sideweb sealer 4436 is located one on either side of the machine in aposition that allows sealing of the upper web to the lower web, forminga single and continuous heat seal between the upper web and the lowerweb, along the outer edges of the upper web, along path 4438 and 4440shown in FIG. 176. A gassing member 4442 is located between the upperweb and the lower web such that the upper web and the lower web can beheat sealed together at paths 4438 and 4440, thereby encapsulating thegassing member 4442 with the upper web 4444 and the lower web 4402, inclose and touching proximity to the gassing member 4442. The gassingmember 4442 is attached and fixed to the machine at the entry end to theupper and lower chambers assembly and otherwise floats along its entirelength. Gas ports 4446 and vacuum recesses 4448 are machined in thegassing member, such that the gas ports 4446 provide directcommunication from a suitable gas source separately to each lowerchamber location 4424, 4426, 4428, and 4430, thereby introducing intothe master containers chosen gases separately and during each cycle ofthe machine. Vacuum recesses 4448 provide communication between themaster containers and a vacuum source via apertures 4452 in lower weband vacuum ports 4450.

Preferably, during each machine cycle, upper chamber assembly 4410 andlower chamber assembly 4412 close toward each other with a clampingforce, and clamping the upper web and lower web with gassing membertherebetween, such that master packs in lower web are enclosed in thecavities in the lower chamber. As can be seen in FIG. 178, the upperchamber 4414 is clamped against the upper web 4444 and the lower chamber4424 is clamped against the lower web 4402 with the gassing member 4442between the upper web 4444 and the lower web 4402, which are sealedalong path 4440. Seals 4468 are provided as required and as can be seenin this closed position, the upper chamber 4414 and the lower chamber4424 provide a substantially airtight assembly. Preferably, afterclosing of the upper and lower chambers together, a vacuum source isconnected to vacuum ports 4450, which substantially evacuates all airfrom within the master packs. Preferably after evacuation of the masterpacks, a suitable gas which may be selected from those gases listedherein, is provided through gas port 4446 and into the master packs4404. The suitable gas is provided at a pressure that exceeds ambientatmospheric pressure and may be provided at a pressure preferablybetween about 0 psi and about 200 psi or more. The gas can be retainedat the desired pressure for a set period of time preferably equal toabout one or more seconds. Preferably, after the set period, suitablegas pressure is reduced to slightly above ambient atmospheric pressureso as to maintain a positive pressure within the master containers butnot at such a high pressure that may cause rupturing of the seal betweenthe upper and lower webs at seal paths 4438 and 4440, after opening ofthe upper and lower chambers.

The upper and lower chambers assembly is then opened and the masterpacks move forward one pitch so as to be located directly between upperchamber 4416 and lower chamber 4426. The upper and lower chambersassembly is then closed and the evacuation and gassing sequence asdescribed for upper chamber 4414 and lower chamber 4424 is repeated,however, the gas provided through the gas port into the closed upper andlower chambers may be a different gas. This sequence of evacuation andpressurized gassing is repeated during each machine cycle in upperchambers 4418 and 4420 with corresponding lower chambers 4428 and 4430.

FIG. 177 shows a cross-sectional view through upper chamber 4422 andlower chamber 4432 with heat bank. Upper chamber 4422 and lower chamber4432 close against each other and heat bank 4458 heat seals the upperweb 4444 to the lower web 4402, at a path that follows the perimeterfully around each master container, so as to hermetically heat seal theupper web 4444 to the lower web 4402 with suitable gas containedtherein. Upper chamber 4422 and lower chamber 4432 open to allow thehermetically sealed master packs 4456 to be carried forward toward theexit end of the machine. The master packs 4456 are slit longitudinallywith a slitter 4462 and cut laterally with a knife 4464 as shown in FIG.157, prior to the ejection of finished master packs from the machine.

In this way residual oxygen that is retained in the cell structure ofthe EPS foam trays, contained in the mater packs, can be exchanged withother suitable gasses. Preferably, gasses such as carbon dioxide can beprovided under pressure so as to dissolve in any free liquids such aswater and oils contained in the perishable goods such as red meat.

Modified and Controlled Atmosphere Packaging

Before disclosure of the preferred methods for conditioning meats priorto packaging, the inventor, without intending to be bound to theparticular theory, now wishes to advance the theory for the formation ofmetmyoglobin in packaged red meats and solutions to the problems ofmetmyoglobin formation, with reference to FIG. 179.

Fresh meats that have been chilled during an adequate storage periodwill contain large quantities of purple colored, de-oxymyoglobin whichis unattractive to typical consumers. When the chilled meat is sliced inambient atmosphere the de-oxymyoglobin that consequently comes intocontact with atmospheric oxygen, will then, by oxidation, convert intooxymyoglobin (referred to as “bloom”) displaying a bright red color thatis attractive to consumers. However, if the sliced meat (or ground meat)is intended to be stored in a low oxygen gas atmosphere, case readycondition, as a way of extending storage life prior to retail display,the oxymyoglobin that has formed after slicing and/or grinding (butbefore subsequent packaging in the low oxygen atmosphere), may providefor undesirable transfer of oxygen gas into the sealed environment ofthe master container. Even though the quantity of oxygen transferred bythe de-oxymyoglobin, is relatively small it can lead to the formation ofundesirable metmyoglobin on the visible surface of the retail packagedred meat. Metmyoglobin is brown in color and is unattractive toconsumers. It is therefore desirable to prevent and/or minimize theextent of such deleterious formation of the metmyoglobin. The apparatusdisclosed in the following subject matter details preventative methods.In order to provide a more detailed description of the conditions underwhich the undesirable metmyoglobin may form, the following known laws ofphysics and natural processes are referenced:

Normal Conditions for Oxymyoglobin Formation

After storage under commercially normal refrigerated conditions incarcass or vacuum packed conditions, freshly sliced beef willpredictably turn bright red (by oxidation of purple coloreddeoxymyoglobin to bright red colored oxymyoglobin) with a virtually 100%probability, when exposed to ambient air.

Optimum Conditions for Metmyoglobin Formation

It is known that optimum conditions for formation of metmyoglobin, atthe surface of sliced, fresh beef muscle exposed to a gas occurs whenthe free oxygen content of the gas is approximately 5000 to 30,000 ppm.

Graham's Law of Gas Diffusion

The rate of gas diffusion is inversely proportional to the density ofthe subject gas.

Relationship Between Density of Gas and Temperature

The density of a gas (and most matter) is inversely proportional totemperature (i.e.: the gas density increases as its temperature isdecreased).

Henry's Law

At a given temperature, the solubility of a gas in a liquid is directlyproportional to the pressure of the gas above the liquid.

The “Mud Puddle Ring” Effect

According to the present inventors observations and independentlyperformed empirical trials, the “Effect” can typically occur,immediately following packaging, when the following prevailingconditions are generally approximated:

1). The subject sliced beef has been allowed to “bloom” as a result ofexposure to ambient atmospheric oxygen immediately prior to packaging.

2). The temperature of the sliced beef is lower than the gas andpackaging materials surrounding it, immediately after packaging.

3). The sliced beef is placed in an “enclosed space” defined by the“retail package” including an EPS foam tray (or other) and a high OTRover wrapping web (the “web”). The “enclosed space” is not completelyfilled with the subject sliced beef and a remaining space (“the space”)is also contained. “The space” is subsequently filled with a “suitablegas” during evacuation of master container.

4). The ratio of beef to gas is low, i.e. the volume of “suitable gas”is relatively low and the volume beef is relatively high, in the“enclosed space”.

5). The “retail package” is placed into a substantially gas barrier“master container” which is evacuated (including the “retail package”)of ambient air and then filled with the “suitable gas”. The compositionof the “suitable gas” can be carbon dioxide, nitrogen and residualoxygen at approximately 100 to <500 ppm. Thereby, substantially filling“the space” and “other space”. The “other space” is defined by theinternal space of the master container but excluding space occupied by“retail packages”.

6). The temperature of “suitable gas” is lowest at the lowest point in“the space”.

FIG. 179 is intended to be representational and not a depiction of theactual “Effect” which is described as follows. Immediately afterpackaging, the highly oxygenated condition of myoglobin (oxymyoglobin),which is present at the surface of the beef slices starts to reduce,releasing oxygen gas inside the enclosed space 1242. At those slicedbeef surface locations shown as 1228, that are in direct and intimatecontact with the web 1232 (such that there is no gas between the beefsurface and the web), the released oxygen gas passes through the gaspermeable web, directly and diffuses into the other space 1242 insidemaster container but outside retail package 1230. This newly releasedoxygen gas is therefore immediately separated and essentially excludedfrom within the retail package. Any further gas contact with this areain direct and intimate web contact is limited to any gas outside theretail package, where the oxygen concentration remains relatively low.However, oxygen gas that is released from the beef surface that is notin contact with the web enters the space 1242 inside the retailage packwhich immediately causes a significant elevation of oxygen concentrationin the small free space under the web. Even though the web is oxygenpermeable the rate of oxygen gas diffusion therethrough is such that itcan take an extended period of time for the oxygen content in the gasunder the web to equilibrate with the oxygen content of gas outside theretail package. Furthermore, the temperature of the oxygenatoms/molecules as they are emitted from the surface of the beef is thesame as the beef which is significantly lower than the temperature ofthe gas in the space and therefore the density of the released oxygen isrelatively high. This condition results in two additional effects. Thediffusion rate is lower (Grahams Law) and because the density is higher,these newly emitted oxygen atoms tend to sink toward the lowest point inthe package and/or remain in contact with the sliced beef surface for alonger period than may otherwise be required. Consequently, the partialpressure of oxygen at the surface of the meat increases and, inaccordance with Henry's Law the level soluble oxygen gas in the meatsurface liquid elevates. The temperature of gas in space 1242 is higherat the highest point and lowest at the lowest point. It can be concludedthat oxygen gas emitted from the beef surface will remain in contactwith the surface of the beef for a more extended period at lowerlocations and therefore higher concentrations will be present at theselower locations. Conversely, lower concentrations will be present athigher locations. Correspondingly, concentrations of metmyoglobin willform in direct proportion to the concentrations of oxygen. Thecomposition of the gas in direct contact with the surface of the beef, alayer of gas that is probably less than about 0.01″ in depth, is theactive gas that has effect at the surface of the beef. Under theconditions described above, the oxygen concentration in this layer canbecome significantly elevated.

The tendency of the relatively heavier oxygen atoms to move toward thelower levels in the space 1242 can cause it to tend to follow thedownwardly disposed surface of the sliced beef, carried with othergasses and liquids that are close to the surface. This condition cantherefore result in an increased level of oxygen concentration at thesurface of the beef which exponentially increases toward the lowestpoint in the space 1242 and is consequently highest at the lowest pointin the space 1242. This results in correspondingly higher (and darker)concentrations of metmyoglobin at the lowest point in the package and,conversely, visible but lower concentrations at the highest point.

A mud pool drying in the sun can appear to be surrounded by parallelrings that are typically gray/brown in color. These rings are lightestat the furthermost point from the center of the puddle and typicallydarkest at the center of the puddle, with a gradual color density changebetween the two points. The color density of metmyoglobin that is formedunder the conditions described above gradually increases between thehighest point in the package where the color is the lightest to thelowest point in the package where the color is darkest. Hence thecomparison with a mud pool drying under the sun.

Eventually, any free oxygen gas released by the reduction ofoxymyoglobin, will become either reabsorbed in the form of metmyoglobinor will be diffused and equilibrated with the modified atmospherecontained throughout the master package. However, the effective,irreversible, deleterious event of formation of metmyoglobin at thevisible surface of the meat will have already occurred and under theprevailing conditions prior to intended retail sale of the meat, willpermanently remain visible.

Subjectively, the above occurs in what can appear to be a confusingmanner. The best most highly oxygenated and therefore red looking beef(as in that having an attractive red “bloom”) prior to packaging in thelow oxygen atmosphere will, with an almost certain predictability,emerge as the worst looking beef after removal from the mastercontainer. Conversely, the worst looking (as in that beef colored bypurple deoxymyoglobin) prior to packaging in the low oxygen atmospherewill, with an almost certain predictability, emerge as the best lookingbeef after removal from the master container.

Other issues of multiple species mass transfer with chemical reaction(i.e. a potential cause for the mud puddle ring problem in packagedfresh meat) are described as follows.

1. Equilibrium between a gas and a liquid is governed by Henry's lawwhich states that the partial pressure of a gas at equilibrium is equalto the Henry's Law constant multiplied by the concentration of the gasin the liquid phase at equilibrium. The gas is oxygen (O2) and theliquid is water (H20).

2. Based on the functional relationship expressed in Henry's law,several conditions can influence the state of equilibrium between freeO2 in the package and O2 absorbed in water.

A. Partial pressure of free O2 in the in-package atmosphere.

B. Temperature as Henry's constant is temperature dependent.

Conversion of absorbed O2 in water due to chemical reaction. (The workreported by Zhao and Wells indicates that in-package absolute gaspressure can vary in fresh packaged meat, either increasing ordecreasing due to a combination of factors including composition,storage time, temperature, pre and postmortem factors, and others. Sincetotal in-package gas pressure can vary, partial pressure conditions ofO2 can vary causing a migration of O2 in and out of water solely basedon consideration of factor A. With respect to factor B, it is likelythat there are thermal gradients that develop across products, from thecenter to the surface, for even slight temperature variations that areexperienced within the package. This would have two results. Thetemperature gradients across a product would help to cause moisturemigration within a product; and the temperature fluctuation wouldpromote a change in O2 equilibrium concentration within water. Ineffect, O2 could be absorbed into water, the water migrate, andsubsequently be deposited somewhere else in the product.

As a result of factors A and B, and the role of chemical conversion, itis likely that some aqueous participation is needed. Given this, thequestion becomes what relative O2 concentration and reaction time isneeded to produce brown metmyoglobin color. If the time is sufficientlylong, factors A and B would operate to move O2, seemingly through theproduct, to a point to produce the mud puddle ring.

Because the in-package gas atmosphere in a closely wrapped productpackage is minimal, there is very limited opportunity for bulkconvective gas movement by mass transfer within the package. Theenclosed space near the permeable web, product and tray are particularlyprone to development of a boundary layer away from free mixing of gasmolecules within a larger, relatively unconfined headspace. Boundarylayer phenomena may include the establishment of a proportionatelocalized gas concentration compared with the free gas concentration.This situation would aggravate the O2 conditions outlined above in point2A and 2B compared with a package with a larger headspace volume.

Once formed on a slice of fresh red meat, metmyoglobin is essentially afixed stain, with unappealing appearance and is generally unacceptableto consumers. On the other hand, oxymyoglobin, which imparts anacceptable red bloom color is attractive to consumers and is thereforedesirable.

The present invention provides methods and apparatus for grinding meatssuch as beef by processing boneless beef through a grinding machine(such as may be supplied by Weiler & Company of Whitewater, Wis., USA)and substantially preventing exposure of the ground meat from contactingambient air until the ground meat is delivered in any suitable retailpackage to a point of sale, such as a supermarket. In this way formationof excessive quantities of metmyoglobin and/or any cause of excessivediscoloration can be minimized. In a preferred embodiment, the meat canbe vacuum packaged after treatment with CO₂ in any one of the methodsdescribed herein.

Meat Grinding Blending and Methods for Controlling Fat

Typically meat packing companies slaughter cattle and then process thedressed carcass by chilling and then dis-assembling the carcass intoportions of meat which can then be, in part, delivered to the point ofsale to consumers, in vacuum packs. However, approximately 40% of thedis-assembled meat is processed at the point of animal slaughter bygrinding and then blending to provide ground meat with a selected fatand lean content as required by the retailer. The fat and muscle contentof the ground meat may be, for example, 20% fat and 80% lean. Currentprocessing methods require that the boneless meat be firstly coarseground then blended, vacuum packaged, delivered to a supermarket orpackaging facility close to the consumer where the coarse ground meat isfine ground and then retail packaged immediately prior to retaildisplay. This process inherently results in excessive exposure of theground meat to ambient atmosphere during the grinding and blendingprocess at the point of slaughter. Furthermore, this process requiresthat relatively large quantities of ground beef are blended together ina single batch. Because it is not possible to dis-assemble a carcass andprovide boneless meat therefrom with a precise and selected ratio of fatto muscle tissue, the typical batch blending process often requiresseveral attempts to produce the desired ratio of fat to lean content.The general industry practice is to deposit selected boneless beef witha fat to lean ratio as close to a desired tolerance as possible. Theselected boneless beef may have a fat to lean ratio of 15% fat to 85%lean+/−5%. The selected boneless beef is then coarse ground and blendedin a batch blender such as can be acquired from Weiler and Company.Typically, a sample of the blended boneless beef is then removed fromthe blender and then can be tested to determine fat and lean contentusing, for example, a device known as an Analray testing procedure.After determining the fat and muscle content of the coarse ground meataddition fat or lean meat is added to the batch blender and the fullbatch is again blended for a period of time and then a second sample isextracted and tested to determine fat and lean content. If the fat andlean content is as required at this point, the batch of coarse groundmeat can be vacuum packaged and stored in refrigerated facilities priorto delivery to the point of retail sale. However if the fat and leancontent is not as required then additional fat or lean meat can be addedto the batch and further mixing is then required. This process is oftenrepeated as many as 5 times or more. Each time the coarse ground meat isblended again it is damaged by the blending process. This damage mayinclude “fat smear” or over heating. Heat is generated during thisblending process and “fat smear” occurs when the meat has been exposedto excessive blending. This procedure is expensive in terms of energy,labor and equipment time. Furthermore, damage to the ground meat isundesirable and yet damage typically occurs as a matter of normalprocess with the currently predominant industry procedures. During theprocess described above the meat is exposed to ambient air and bacteriasuch as E. Coli and other dangerous bacteria can be present in theblended ground meats. Excessive blending can cause the bacteria tospread throughout the batch of meat in the blender.

Ground foods such as ground beef have been produced by processing inmeat grinding and blending equipment and associated equipment, such asblending and processing equipment manufactured by Weiler/Beehive. Theequipment can be viewed at the following web site:www.meatingplace.com/com/beehive

Ground meat such as ground beef is produced by processing selectedportions of boneless meat, including fat and muscle tissues, through agrinding machine. The relative quantities of fat and muscle contained inany batch of the portions of boneless meat is typically arranged tocorrespond with set industry standards. The batch of boneless meat mayinclude about 93% muscle tissue and therefore the balance of about 7%would be fat. The following list of items 1 to 5, shows the fat andmuscle tissue content of some typical industry specifications forboneless meat: TABLE 1 Muscle Fat Item Tissue Tissue 1 93% 7% 2 90% 10%3 75% 25% 4 65% 35% 5 50% 50%

Although the industry standards are established, it is difficult toproduce large quantity of boneless beef to any specification or ratio offat and muscle. This difficulty can arise as a result of geneticvariation in the animals from which the boneless meat is harvested.Consequently, there is often variations that could be as much as +/−2%to 3%, which corresponds to a possible variation of up to 6% and perhapseven more, in the actual fat or muscle content of the boneless meat.

Typically, consumers can purchase fine ground beef with a fat contentthat is specified and clearly marked on any retail package. The fatcontent may be specified to 10%, 25%, or 30% and it is illegal to sellsuch retail products to consumers if the fat content is higher than theamount shown on the retail package. Therefore, producing retail packagesof ground beef with a fat content of, for example, 25%, may be achievedby grinding a known quantity of Item 2 (listed above) and blending thiswith a known, measured and corresponding quantity of Item 4 (listedabove). The fat content of the resulting ground beef can be measured butit is common for the fat content variation in the initial quantity ofthe boneless beef items to vary to such an extent that a compensatingprocedure must be accommodated during production of the product forretail packaging. This compensating procedure can often result inproduction of ground beef that has a muscle content that is higher thanis specified on the retail package. The consumer, however, only pays forthe ground beef according to the fat content shown on the retailpackage. Thus a loss of profit for the ground beef producer can beincurred.

A quantity of boneless beef, with a specified muscle and fat content,say Item 5, is loaded into a hopper which is connected directly to aprimary meat grinder. The portions of meat are progressively carried, byaugers and compressed into a tubular conduit with a perforated grindingplate fitted across. The grinding plate is typically manufactured fromsuitably hardened steal and the perforations may include drilled andreamed holes of a chosen diameter, which may be about 0.5″ diameter, andwhich extend completely through the grinding plate. The primary grindertypically produces coarse grinds with the diameter of the meat piecescorresponding with the diameter of the drilled and reamed holes in thegrinding plate.

After primary grinding a quantity of Item 5 may be blended with aselected quantity of coarse ground Item 4. After the blending of Item 5with Item 4 the resultant mix is processed through a secondary finegrinding machine prior to portioning and retail packaging. The secondaryfine grinding machine may be similar to the primary coarse grindingmachine except that the grinding plate can be drilled and reamed withholes of less than about 0.25″ diameter.

Typical fine ground meat for retail packaging and sale to consumers maybe produced with fat and muscle content as shown in the following table:TABLE 2 Muscle Fat Item Tissue Tissue 1F 90% 10% 2F 75% 25% 3F 65% 35%

The existing grinding, blending and processing equipment, such asWeiler/Beehive equipment, has been demonstrated as effective forgrinding meats of various types. However, little has been proposed toimprove the quality of the ground meats by, for example, arrangingequipment in such a manner so as to substantially prevent contact of theground meats with air and/or atmospheric oxygen during the grinding andblending process. Meats are ground and blended in such a manner so as toproduce ground meats including a product with a desired ratio of muscleand fat content. The conventional equipment does not allow forcontinuously and automatically grinding and blending the ground meats insuch a manner so as to continuously produce quantities of ground meatsto an exact and predetermined muscle and fat content.

The present invention provides methods, systems and apparatus toautomatically and continuously grind, condition and blend the groundmeat products with improved accuracy of muscle tissue to fat tissueratio, so as to minimize losses to the processor. The ground meat canthen be packaged in suitable packaging that will enhance the keepingqualities of the products and provide a safer method of delivering thegoods to consumers.

Meat Grinding and Conditioning Apparatus

Having described tray construction, web covers, master container andassociated methods for making and packaging, it is now appropriate todiscuss apparatus and methods for treating the perishable food itemsthat are to be packaged by those methods herein described. A logicalstarting point is a method and apparatus for grinding and conditioningmeat.

Referring to FIG. 180, a cross-sectional view of a preferred grindinghead 1300 constructed according to the present invention is shown.Preferably, grinding head 1300 is attached to a source for thecarbonation of liquids and water contained in ground meats. Meat 1310 isprocessed through grinding head 1300 of a meat grinder 1302 anddeposited into vessel 1304. Vessel 1304 is substantially sealed from theexternal atmosphere. Preferably, entry point 1306 and exit point 1308are such that when compacted meat 1310 fills the grinding head 1300adjacent to the cutter 1312 and similarly compacted ground meat 1316fills the exit point 1308 of vessel 1304 adjacent to the end ofscrew-auger 1314, the vessel 1304 can be filled with a gas such ascarbon dioxide under pressure. Preferably, pressure is kept aboveambient atmospheric pressure therefore assisting the dissolving processof carbon dioxide into water in meat. Preferably, screw-auger 1314 isattached to a driver (not shown) and rotated so that the ground meat iscarried forward and as it travels down the length of the screw auger1314, the space between the tapered flights 1320 of the screw auger 1314gradually is reduced, thereby compressing the ground meat just prior toejection at exit point 1308, thus providing a seal of the vessel 1304from ambient atmosphere.

This embodiment provides a cost effective method of increasing thepressure of carbon dioxide and elevating the quantity of dissolvedcarbon dioxide in water and ground meat to a desirable level. Gasprovided under pressure into the vessel may include, preferably, asuitable blend of carbon dioxide and other gasses such as nitrogen,stabilized chlorine dioxide (stabilized chlorine dioxide brand nameOxine), helium, and other inert gases, but substantially excludingoxygen, and including an amount of carbon dioxide of about 5% to about100% by volume or weight.

One embodiment of screw-auger 1314 is shown but alternates may bearranged in other configurations such as when connected directly to andparallel with screw auger 1318 and housed in a tube that has an internaldiameter slightly larger than the outside diameter of screw auger 1314,that is also in line and parallel with screw auger 1318. Such anarrangement passes ground beef through a pressure box or vessel andexposes the ground beef to carbon dioxide or other suitable gasses at agas pressure above ambient atmospheric pressure.

Preferably, suitable blends of gasses can be produced and/or blended atthe point of use and injected into vessel 1304 and grinding head 1300 atports 1322. Preferably, a stainless steel or plastic extension tube isfitted to the flanges of the “downstream” egress/exit point of thepressure box (so as to allow all ground meat to pass through the tube)and the blend of gases is injected into the tube so as to substantiallyexpel atmospheric gasses and oxygen from the tube such that the blend ofgasses remains in contact with the meat within the tube. The tube mayhouse an auger type screw arrangement to transfer ground meat inside thetube. The auger has apertures and holes drilled that connect to apressurized supply of gas.

When the gas is injected through the drilled holes and apertures,exposure of the ground meat to the gasses will be maximized. The groundmeat can be shaped or profiled and cut into portions of specified sizeand directly loaded into packaging while enclosed in a space containingthe gas.

Temperature of the gas or blend of gases can be preferably controlled,and may include individual gases in varying relative proportions so asto optimize the cooling of the meat simultaneously while providingsufficient carbon dioxide to allow maximized dissolving of carbondioxide into the water contained in the freshly ground meat contentliquids.

Gasses will most preferably be injected into the grinding head at apressure that will purge or cause to be expelled, substantially allatmospheric gases from the grinding head and both upstream anddownstream of the grinding head. Preferably, covers (not shown) willenclose the portions of the grinding process, package filling andpackaging equipment to limit and control escape of dangerous levels orquantities of carbon dioxide or other gasses that may cause damage tohealth of any machine operators and/or personnel. Preferably gasextraction fans can be located adjacent to the equipment to ensure thatsafety to operators of the equipment is maintained.

Covers will also preferably restrict egress of atmospheric gasses, suchas oxygen, from contacting the freshly ground beef and/or meat prior topackaging and hermetic heat sealing of each package. Such apparatus willsubstantially inhibit the oxidation of deoxymyoglobin contained in thosefreshly ground meat portions that were previously not exposed toatmospheric oxygen.

Alternatively, a suitably concentrated solution of carbonic acid (carbondioxide dissolved in distilled water) can be injected into the grindinghead 1300 at port 1322, or mixed with the meat portions immediatelyprior to grinding such that it becomes mixed with the meat in thegrinding process. Preferably, subsequent to grinding, the ground meatcan be carried through a tube or “tunnel” that is filled with carbondioxide.

Alternatively, prior to grinding the meat, the portions of meat arepassed through a carbon dioxide tunnel to evaporate a quantity of freewater equal to the amount of carbonic acid injected into the grindinghead. Carbonic acid solution may be sprayed onto the portions of meatwhile passing through the carbon dioxide tunnel. Preferably, solidcarbon dioxide (“snow”) may be dissolved into water to produce carbondioxide solution (carbonic acid and water). A measured quantity of snowmay be injected into the grinding head at a point immediately adjacentbut located on the up stream side of the grinding head such that, duringthe grinding process, the solid carbon dioxide is blended with the meatso as to substantially cover the surface of the meat particles aftergrinding. Preferably, a controlled and continuous weighing and feederdevice may be used to accurately dispense the solid carbon dioxide.

The process of the present invention advantageously inhibits the growthof bacteria on the surface of the meat portions and particles andmaximizes shelf life of the meat for a longer period than the shelf lifeperiod that would otherwise be possible without an increase of dissolvedcarbon dioxide in surface water and also minimizes exposure of groundmeat to atmospheric oxygen while in processing from grinder to retailpack. This reduces the normal event of the oxidation of deoxymyoglobin,contained in the meat prior to cutting, to oxymyoglobin and then thereduction back to deoxymyoglobin after packaging in the packages that donot contain oxygen. Alternatively, freshly ground or cut meat may bepassed through apparatus for removing and collecting some of the freesurface liquid in a continuous or batch process such as with acentrifuge. The liquid is then processed by way of pasteurization at atemperature that does not cause any undesired effects on the ultimateoxidation of the deoxymyoglobin to oxymyoglobin to produce a desirablefresh red color at the point of sale. The liquid can also be exposed tocarbon dioxide by mixing with solid or gaseous carbon dioxide. Aftersufficient carbon dioxide has dissolved into the liquid, the liquid canbe sprayed onto meat or other types of goods in a continuous productionprocess.

Alternatively, in another embodiment of the present invention, thecarbonation of the free surface liquid may be achieved by including afurther step in the process/method of producing modified atmosphereretail packages. Fresh meat can be packaged in a substantially gasimpermeable plastic package including a thermoformed tray and flexibleplastic lid, hermetically sealed to the tray. The process involveslocating the tray (with fresh meat) into an enclosed chamber and thensubstantially removing atmospheric air from within the chamber beforethen filling the chamber with a blend of desired gases followed byhermetically sealing the lid to the tray. The present invention providesan apparatus and method for, after substantially evacuating the chamberand filling the chamber with the desired gas, compressing the gas (blendof N₂ and CO₂ or 100% CO₂) within the chamber to an optimized pressureof between slightly above ambient atmospheric pressure and up to 6 bar(6 times the atmospheric pressure). The gas pressure within the chamberis then lowered to ambient pressure (1 atmosphere) and the package isthen hermetically sealed. This process of carbonation increases thequantity of carbon dioxide that is dissolved into the liquid in the meatand goods. After hermetic sealing of the package, the liquid issubstantially saturated with dissolved CO₂. This inhibits furtherdissolving of CO₂ into the liquid, that may otherwise cause the packageto collapse, and can also extend the shelf/storage life of the meat whenheld under refrigeration (at preferably between about −2 to about 4degrees C.).

Meat Carbonation Equipment

Referring now to FIG. 181, another preferred pressure vessel assemblyconstructed according to the present invention is shown. The pressurevessel 1600 preferably saturates any given quantity of ground meat, withabsorbed or dissolved gasses and particularly carbon dioxide gas whilealso controlling the temperature of the ground meat and minimizing oreliminating freezing of the ground meat during the process.

An adapter tube 1602 is shown connecting a meat grinder 1604 to thepressure vessel assembly 1600 and is most preferably provided with anairtight connection. Compacted meat 1606 is shown within the meatgrinder 1604. Preferably, the compacted meat 1606 is forced throughholes in a plate and cut by a rotating blade in a manner as is typicallyincorporated in most meat grinders and is well known to manufacturersand users of meat grinding equipment. Preferably, compacted meatprovides a seal to substantially prevent escape of pressurized gassesthat may be provided to the pressure vessel. Preferably, a port 1608 isprovided in a section of the meat grinder 1604 to allow injection ofgasses such as carbon dioxide or blends of carbon dioxide nitrogen orany other suitable gas. Preferably, injection of the gasses into port1608 substantially purges air that is in contact with the meat justprior to grinding and displaces the air with the desired gas.Preferably, the gasses may include a gas blend of carbon dioxide andnitrogen where the percentage of carbon dioxide is about 95% and thebalance of about 5% includes nitrogen. Preferably, the interior ofpressure vessel 1600 is substantially isolated from atmospheric air andis fitted with a removable dome 1610. Removable dome 1610 can facilitateeasy access for general cleaning and sanitizing purposes. Preferably,the main portion of pressure vessel 1600 is enclosed by a jacket 1612providing a space between the jacket 1612 and walls of pressure vessel1600. Preferably, temperature is controlled by circulating fluid throughjacket through port 1614 and extracted through port 1616. Across-section of the vessel 1600 taken along line P-P, through thejacket and pressure vessel walls is shown in FIG. 182 for clarity.

Preferably, a port 1622 is provided at the apex of removable dome 1610providing a port to inject gasses and other substances such as O₃, F₂,H₂O₂, KMnO₄, HClO, ClO₂, O₂, Br₂, I₂, or any combination thereof andflavors into or alternatively extract from within the pressure vesselthrough port 1622. Alternatively, a gas blend is injected into thepressure vessel through port 1622 and maintained at a pressure of about25 psi. Most preferably, a gas blend including nitrogen and/or carbondioxide and/or ozone (O₃) will be provided into pressure vessel via port1622. Water and oils contained in the ground meat can then absorb carbondioxide until it becomes substantially saturated and cannot absorb anyadditional carbon dioxide. Preferably, a controller to maintain and/oradjust and vary pressure of the gasses within the pressure vessel, asdesired, is also provided but not shown. Preferably, a side port 1624 isprovided in the wall of the pressure vessel through which ground beefmay be provided into the pressure vessel 1608 for further processing inthe pressure vessel assembly. Preferably, the size of the pressurevessel can be adjusted to suit requirements. The dimensions of lengthand height may be increased or decreased to accommodate the requiredprocessing capacity of the first pressure vessel assembly. The lower endof the pressure vessel 1600 is attached to a horizontally displaced tubesection 1624 within which an auger 1628 is mounted. Preferably, auger1628 includes passageways and holes 1646 provided so as to allowinjection of gasses therethrough by connection to a source of gassesthrough port 1648, thus substantially maximizing exposure of the groundmeats to direct contact with the gas blend. Tube section 1634 has alength dimension L which can be increased or decreased according torequirements. Preferably, auger 1628 is attached to a driver (not shown)that can provide a force to rotate auger 1678 in a direction such thatground meat will be transferred through horizontally displaced tubesection 1626 and toward a tapered tube section 1632. Preferably, driverhas the capacity of rotating auger 1628 at a desirable speed which canbe adjusted as may be required to optimize throughput of ground meat byfirst pressure vessel assembly.

Fine ground meat passes into the pressure vessel 1600 and accumulatesuntil the upper level of accumulated ground meat is adjacent toproximity switch 1650. Switch 1650 sends a signal to the variable speeddrive motor which motor starts to slowly rotate auger 1628. Ground meatcontinues to accumulate and when level reaches a point adjacent toproximity switch 1652 variable drive motor is accelerated to a higherspeed. The level of ground meat may continue to elevate and when thelevel reaches proximity switch 1652 drive motor speed is increased tomaximum speed causing the level of ground meat to drop below a leveladjacent to 1654 at which point the drive motor slows down to a lowerspeed. When the level of ground meat drops to a level below 1650 thedrive motor is signaled to stop. Therefore, in this fashion, the levelof ground meat within the pressure vessel 1600 can be maintained at apoint between the lowest proximity switch 1650 and the highest proximityswitch 1652.

Preferably, tapered tube section 1632 has ports 1634 and 1636 to allowinjection of gasses into section 1632 or allow gasses to be extractedfrom within the tapered section by passage. Preferably, additional portsmay be provided through any part of apparatus walls as may be requiredto optimize efficiency and operation of pressure vessel assembly. Atransfer section 1630 is located at the egress end of tapered tubesection 1632. Preferably, section 1630 is provided with a port throughwhich gasses may be injected into or extracted from within section 1630.Preferably, a desired profile can be varied by interchanging an extrudedprofile section 1640. Preferably, the continuous length of extruded foodproduct can be severed by a cutting device such that pieces of extrudedfood can be provided with specified and desired lengths. The pieces ofextruded food can then be packaged into packages of suitable size. Suchan extruded profile section 1640 is attached to the egress end of thetransfer section 1630. A cross-section through section 1640 is shown inFIG. 183 where a rectangular profile can be seen. Ground meat can becompressed by auger 1628 and thereby forced through section 1640.Preferably, compression of the ground meat through the profiled sectionprovides a similar rectangular profile to the ground beef as it passesthrough the egress end of section 1640.

A side view and end view of an alternative extruded profile section 1640in the form of a manifold is shown in FIGS. 185 and 184. Preferably,manifold 1642 includes a series of three tube profiles through whichground meat can be extruded. Such a process can provide three separatestreams of profiled ground meat. The manifold 1642 may include one orseveral streams of profiled ground meat. A tube of similar internalcross-section to the stream of ground meat may be connected to eachstream of ground meat and thereby contain each stream of ground meatseparately within a corresponding number of tubes so as to allowtransfer of the profiled ground meat to other processing equipment suchas automatic ground meat patty production equipment or a second pressurevessel. The tube(s) will thereby provide protection to the ground meatand substantially isolate it from contact with external contaminants oratmosphere.

Preferably, a 3 way valve (not shown) can be inserted between transfersection 1630 and profile section 1640. The 3 way valve can be attachedto section 1630 and section 1640 in a substantially airtight fashion soas to provide direct connection to each other or a connection to analternative tube connected to other equipment or to port 1624.Preferably, this provides diverting the ground meat to other equipmentfor further processing or, as may be required at the start of a periodof production, diversion of the ground meat into a first pressure vesselthrough port 1624 for additional processing to ensure that the groundmeat is substantially saturated with dissolved carbon dioxide or othergasses. After the ground meat has been re-processed, which may requirereturn to pressure vessel 1600 via port 1624 repeatedly, the three wayvalve can be switched to direct passage of the ground meat through theextruded profile section 1640 or other equipment for further processingor retail packaging. Preferably, valves (not shown), most preferablyautomated valves to close all ports shown in FIG. 181 and any othersthat may be provided, in a substantially airtight manner, are providedto each port but not shown.

As can be learned and understood with the foregoing description anadequately effective gas tight seal can be provided by compacted meat1606 within meat grinder 1604. Furthermore, auger 1628 can be arrangedso as to fit closely within transfer sections 1632 and 1630 such thatwhen 1628 is rotating, during normal operation of the apparatus, groundmeat will become compacted within 1632 and 1634 and around auger 1628and thereby provide an adequately effective gas tight seal. Therefore,gas pressure within the pressure vessel 1600 can be increased to aboveambient atmospheric air pressure as required and maintained at aselected pressure by a controller to maintain and/or adjust and varypressure of gasses within the pressure vessel 1600, as desired. Thegasses within the pressure vessel 1600 will therefore be substantiallycontained between the compacted meat at 1606 in the meat grinder andcompacted meat 1656, within transfer sections 1632 and 1630 at a desiredpressure. Pressure can therefore be maintained at a pressure most suitedfor rapid absorption by water and oils in the ground meat containedwithin the apparatus during operation and transfer of the ground meatthrough the apparatus.

Preferably, second and additional pressure vessel assembly of similarconstruction to the first pressure vessel assembly, can be provided andattached to the first pressure vessel assembly via an adapter tube so asto provide direct passage of the ground meat from the egress point atthe extruded profile section 1640 by way of a tube connected directly tothe adapter tube 1602 into the second pressure vessel assembly therebyproviding direct communication to the second pressure vessel. Afterpassage of the ground meat through the first pressure vessel it cantherefore be passed directly into a second pressure vessel. Preferably,the second pressure vessel is attached to a vacuum pump via a similarport to that as shown as port 1622 in FIG. 181. Preferably, the portshown as port 1624 is not provided in the second pressure vessel. Asuitable gas such as nitrogen is injected into ports provided in thesecond pressure vessel assembly which are shown as ports 1608, 1634 and1636 and the nitrogen gas is also injected through ports and passagewaysin auger, also provided in the second pressure vessel assembly and shownas 1628 in the first pressure vessel assembly. The gas pressure withinthe second pressure vessel assembly is maintained at approximately apressure equal to or higher to the prevailing atmospheric pressure. Theground meat is passed through the second pressure vessel assembly andthrough extruded profile section and into other equipment as requiredfor packaging and or further processing. Passage of the ground beefthrough the second pressure vessel assembly removes free carbon dioxidethat may remain within the voids contained within the ground meat andreplaces it with a gas such as nitrogen.

A preferred embodiment is to provide a method of substantiallyrestricting the escape of any gasses, such as carbon dioxide or ozone,from an apparatus, that may be hazardous to the wellbeing of operatorsof the apparatus. This can be achieved by locating the apparatus, suchas shown in FIG. 181, within a confined space such as an enclosed roomor other enclosure that is substantially filled with an inert gas suchas nitrogen. The enclosure may include several parts and be arranged tocover only certain parts of the apparatus. The apparatus can be arrangedsuch that certain parts are exposed to allow access or loading.Preferably, the gas contained in the room or enclosure will besubstantially nitrogen with a residual oxygen content of less than20,000 parts per million. The enclosures or room can be extended toenclose or house other equipment such as conveyors and packagingapparatus that may be used to process and package the ground meat. Suchan arrangement would most preferably isolate the ground beef fromcontact with gasses containing oxygen in concentrations greater that20,000 parts per million, or greater than 300 parts per million, andallowing the ground meat, which may be ground beef, to be packaged in avacuum pack or a modified atmosphere package containing a gas thatincludes a blend of desired gasses but containing residual oxygen of notmore than 500 parts per million. The gas contained within the enclosuresor the room may be pressurized and vented to a convenient and safe pointinto the atmosphere.

Meat Carbonation System

In another preferred embodiment a series of enclosed vessels which maybe pressure vessels, can be connected together, in series, via suitableconduit means with a positive displacement pump located between eachpressure vessel and connected to the conduit means such that a pump cantransfer product such as ground meat, by pumping means, from a firstpressure vessel to a second pressure vessel. Goods such as ground meatcan be transferred directly from a grinder into a first pressure vesseland a first pump can transfer the ground meat from the first pressurevessel to a second pressure vessel. A second pump can be provided totransfer the ground meat from the second pressure vessel to a thirdvessel and a third pump can be provided to transfer the ground meat fromthe third vessel to a fourth vessel. Any desired number of vessels andpumps may be assembled in series so as to provide a method oftransferring the ground meat progressively from the first vessel tosubsequent vessels as may be required. Gases and/or other goods andmaterials may be transferred by any suitable means into any of thevessels at any suitable temperature and pressure. Blending and mixingdevices may be installed in the vessels, as may be required, and anysuitable means of controlling and adjusting temperature of goodstransferred into and from the vessels can be provided. In this way eachvessel can be separately and independently controlled and arranged witha holding capacity to accommodate any desired quantity of ground meat,with selected gases and other materials provided therein, and held atany chosen temperature and pressure. Each pump can be arranged toseparate each vessel such that temperature and pressure can beindependently adjusted in each of the vessels.

In a preferred embodiment, for example, fat and muscle tissue containedin a quantity of boneless beef can be separated into a first quantityand a second quantity where the first quantity includes only muscletissue which is then ground or cut into suitably sized pieces and thentransferred directly into a vessel containing a suitable oxygen free gasand held at a temperature of 140 degrees F. for a period of timesufficient to substantially kill any bacteria contained therein. Thesecond quantity including only fat can be transferred into a secondvessel and subjected to ultra high pressure (UHP), exceeding 80,000 psi,so as to substantially kill all bacteria contained therein whilemaintaining the second quantity of fat at a temperature of not more than104 degrees F. The first quantity of muscle tissue can be chilled to atemperature below 100 degrees F. and processed by extrusion to provide afirst continuous stream of muscle tissue with a desired cross-sectionalprofile that can be arranged to be similar to the profile of the musclecomponent of a typical New York strip. The second quantity of fat can bechilled to a temperature below 100 degrees F. and extruded to provide asecond stream of fat with a profile similar to the fat component of aNew York strip. The first stream of profiled muscle tissue and thesecond stream of profiled fat can be then be combined into a singlestream of muscle tissue and fat and the temperature of the single streambe reduced to about 29.5 degrees F. In this way, a substantiallybacteria free, continuous stream of extruded muscle and fat having across-sectional profile similar to a New York strip can be producedwhich can then be sliced into suitable portions prior to retailpackaging.

In this way, ground meat (and other meats) can be processed so as tosubstantially prevent the formation of oxymyoglobin immediately aftergrinding. The ground meat can then be retail packaged in a low oxygenpackage such as a master package system as described herein anddelivered to the point of sale in a de-oxymyoglobin condition. Thepackage can be removed from the de-oxymyoglobin condition immediatelyprior to retail display so as to allow generation of the consumerappealing red color or “bloom” for the first time after grinding.

Meat Grinding and Conditioning Apparatus

Referring now to FIG. 186, a meat grinding assembly constructedaccording to the present invention includes a first and second meatgrinders that are in direct communication via a pressure vessel 1700.Preferably, first meat grinder 1702 is fitted with an auger 1704 andmeat grinder 1702 is attached to pressure vessel 1700 via adapter tube1706 thereby providing direct communication to transfer ground meat thathas been ground by grinder 1702 directly into the pressure vessel 1700.Preferably, adapter tube 1706 is provided with a substantially gas tightseal at the point of connection to pressure vessel 1700 such thatpressurized gas that can be provided into 1700 will not escape.Preferably, the adapter tube 1706 is fitted with a valve (not shown),such that when grinder 1702 has completed grinding and no compacted meatremains in the grinder, the valve can be closed thereby closingcommunication between the pressure vessel 1700 and grinder 1702. Closingthe valve can thereby allow continued processing of any coarse groundmeat that may remain in pressure vessel 1700 with gas provided thereinunder pressure and above ambient atmospheric pressure as required anduntil all coarse ground meat contained in the pressure vessel 1700 hasbeen processed through second fine meat grinder 1738 and into downstreampressure vessel 1730. Furthermore, if so desired an additional valve,similar to the valve at grinder 1702, can be provided in the adaptertube 1718 so as to allow further processing of the fine grinds in thepressure vessel 1730.

Preferably, pressure vessel 1700 is fitted with a removable dome 1708 inwhich is provided a port 1710. Preferably, the lower portion of pressurevessel 1700 is attached to a housing containing auger 1712 which isdirectly attached to a variable speed drive (not shown) that can rotateauger 1712 in a direction that causes coarse ground meat to be urgedinto and through blade 1714 and plate 1716. Preferably, an adapter tube1718 is fitted so as to provide direct communication to pressure vessel1730 Preferably, proximity switches 1720, 1722 and 1724 are convenientlylocated in walls of the pressure vessel 1724. Preferably, proximityswitch 1720 is located at a point higher than the location of switch1724, and switch 1722 is located between switches 1720 and 1724.

Pieces of meat are placed into a hopper (not shown) attached to firstmeat grinder 1702 and auger 1712 is rotated to cause pieces of meat tobe urged through a rotating blade and a perforated plate 1716. Compactedmeat 1726 accumulates in a compressed condition just prior to passingthrough blade 1736 and plate 1716, providing a gas tight seal betweenthe grinder 1702 and the pressure vessel 1700. Coarse ground meat passesinto pressure vessel 1700 and accumulates until the upper level ofaccumulated ground meat is adjacent to proximity switch 1724.Preferably, switch 1724 sends a signal to a variable speed drive motor(not shown) connected to shaft 1728 which starts motor to slowly rotateauger 1712. Coarse ground meat continues to accumulate and when levelreaches a point adjacent to proximity switch 1722, the variable drivemotor is preferably accelerated to a higher speed. The level of groundmeat may continue to elevate and when the level reaches proximity switch1720, preferably the drive motor speed is increased to maximum speedcausing the level of ground meat to drop below a level adjacent toswitch 1722 at which point, preferably, the drive motor slows down to alower speed. When the level of ground meat drops to a level adjacent toswitch 1724, preferably, the drive motor is signaled to stop. Therefore,in this fashion, the level of ground meat within the pressure vessel1700 can be maintained at a point between the lowest proximity switch1724 and the highest proximity switch 1720. Preferably, meat iscompacted at just prior to passing through rotating blade 1714 andperforated plate 1716, thereby providing a gas tight seal betweenpressure vessel 1700 and pressure vessel 1730.

In this fashion compacted meat remains in a compacted condition atlocation 1732 and 1726 providing gas tight seals. Preferably, a desiredgas or blend of gasses can be injected into pressure vessel 1700 at adesired pressure. Preferably, gas pressure is slightly above ambientatmospheric pressure or up to 150 psi and is maintained at desiredpressure by metering and gas pressure regulating equipment (not shown).In this fashion gas can be continuously injected into the pressurevessel 1700 and maintained at a desired pressure at a rate equal to therate of absorption of gasses by the ground meat. The meat and groundmeat may be compacted to provide substantially gas tight seals otherthan as described herein while providing for a continuous productionprocess of meat treatment during the meat grinding procedure. Productionspeed can be adjusted to optimize the gas absorption (and contact withsurface of the ground meat) at a desired rate while maximizing output ofthe apparatus and equipment.

In yet another preferred embodiment, pressure vessel 1700 and/or otherpressure vessels attached thereto, preferably are provided with valves,that can be opened and closed, and that are provided at all ports,adapter tubes, entry and egress apertures in the pressure vessel(s), soas to enable isolation of the pressure vessel(s) from external ambientatmosphere. Preferably, when isolated, gas pressure within the pressurevessel(s) may be adjusted to a suitable and adjustable pressure belowand/or above ambient atmospheric pressure. Preferably, the gas pressure,in the pressure vessel, may be increased and decreased in a pulsatingand/or oscillating frequency and pattern that can provide for theefficient removal of undesirable gasses and the replacement withdesirable gasses at a desired pressure.

Meat Processing System

A processing system is disclosed including a meat grinder and aprocessing and blending tube with three augers to transfer the meatthrough the system. The tube includes a heat exchanger to maintaintemperature and ports for the introduction of conditioning gases.

FIGS. 187-189 discloses a preferred apparatus constructed according tothe present invention arranged to process perishable foods such asground beef. Preferably, the apparatus can be assembled in a gas tightmanner with components manufactured from any suitable materials such asapproved stainless steel or plastics. Preferably, the assembledapparatus may be arranged in a horizontal disposition or with devices toadjust the horizontal disposition to any desirable angle of repose.

Apparatus 5600 includes an enclosed vessel 5624 of circularcross-section profile, with end enclosures 5602 and 5604. Preferably,vessel 5624 can be arranged to contain any suitable gas at any suitableinternal gas pressure and at any suitable temperature. Preferably, thetemperature of the gas is controlled. Preferably, vessel 5624 can befitted with drivers 5614, 5616, 5618 and 5620 attached thereto atsuitable convenient locations and as required to provide driving forcesto a round blending tube, shown as 5622, located inside vessel 5624.Preferably, the drivers can be controlled to drive the tube 5622 at asuitable constant and variable speed. The tube 5622 engages with fourdrive wheels, all shown as 5626 for clarity, and tube 5622 is supportedthereon, but otherwise is free from contact with other components exceptfor suitable contact with seals as may be required at each end of thetube 5622. Preferably, drive wheels 5626, are engaged to thecorresponding drivers 5614, 5616, 5618 and 5620. In this way, the tube5622 is retained by the drive wheels, 5626, in a horizontally disposedposition or as may be otherwise required. Preferably, pressure vessel5624 is fitted with vent 5628 which can be provided with a valve (notshown) to allow any excess liquids or gases to be drained therefrom. Avent with valve and venturi, 5632, can be fitted to vessel 5624.Preferably, any desired number of vents with valves and venturis can befitted to the vessel 5624. Preferably, venturis can be arranged toprovide gas injection into space 5636 in such a manner that will causethe injected gas to flow along space 5636 and then through tube 5622, ina desired direction at a suitable velocity.

The tube 5622 is arranged inside the vessel 5624 and passageway 5636 isthereby provided between the outer surface of the tube 5622 and theinner surface of vessel 5624. Gas can therefore be provided inside thepressure vessel and in the passageway 5624. Preferably, any suitable gastemperature controller may be arranged such as by arranging a heatexchanger 5638 connected to the vessel 5624 as shown. Preferably, afirst and second suitably sized tubes, 5640 and 5642 are attached indirect communication with vessel 5624 such that gas can pass between thetubes and the vessel 5624. Preferably, tube 5640 is connected to theheat exchanger 5638 and another connecting tube 5644 is attached to agas blower 5646 which in turn is connected to the connecting tube 5642.In this way gas can pass through tube 5640, into and through the heatexchanger 5638, through tube 5644, into and through the gas blower 5646,and through connecting tube 5642. Preferably, a barrier 5648 is locatedin space 5636 which can follow the outer circumference of tube 5622 soas to substantially inhibit gas passing therethrough. In this way, whengas blower 5646 is activated, gas can be drawn in from space 5636 on oneside of barrier 5648, through tube 5640 and passed through tube 5642 andback into space 5636 on the opposite side of the barrier 5648.Preferably, this provides recirculation of any suitable gas along thespace 5636, through tube 5622, back into space 5636 and again throughthe heat exchanger 5638. The gas can be re-circulated and repeatedlypassed through heat exchanger, 5638, to maintain the gas at a desiredtemperature. A tube shown as 5650 is provided to allow suitable gas tobe injected into the heat exchanger 5638. Preferably, the suitable gascan be provided in a liquid or high pressure condition and allowed toexpand in the heat exchanger 5638, and thereby cause a lowering oftemperature. Suitable gas can then pass from heat exchanger 5638 andinto tube shown as 5652 which is connected to tube 5644. Alternatively,suitable gas can be allowed to escape through tube 5654 and valve 5656.In this way, by controlling the flow of gas, the internal temperature ofvessel 5624 and all other items therein can be controlled. During there-circulation of gas through tube 5622 and heat exchanger 5638, aquantity of water, contained in the grinds, may evaporate and condensein heat exchanger 5638. The quantity of condensed water in the heatexchanger may be processed, sterilized and carbonized, by dissolvingcarbon dioxide therein and then injected into the grinds through venttube 5658. Preferably, tubes 5652 may be provided with pressureregulators and valves to allow excess gas to escape therethrough, fromvessel 5624 at a suitable rate and in such a manner as to maintain thetemperature of the gas within a temperature range of plus or minus about0.5 degrees F., or at any other suitable temperature range. Preferably,the suitable gas and/or any other suitable substances can be provided invessel 5624 at any suitable gas pressure to facilitate dissolving of thegas and/or substances into the ground meats contained in the tube 5622.In this way, the suitable gas can be controlled to either chill or heatthe ground meats being processed in tube 5622, and by the apparatus.

Referring now to end enclosure 5602 with a plurality of apertures. Cover5660 is located over an inspection access hole so as to provide aconvenient access into the apparatus for any purpose such as forcleaning. Preferably, a vent 5662 is provided to allow excess gas toescape. Preferably, vent 5662 can be attached to suitable valves withgas pressure regulators as may be required to control gas pressure. Atube 5664 is located through a tube in the wall of end enclosure 5602.Preferably, tube 5664 connects to a nozzle 5666, that can be arranged toprovide temperature controlled water or other liquids, at any suitablepressure into the inner space contained within tube 5622. Preferably,the water or other liquids can be used to clean the internal surfaces ofthe apparatus after use of the apparatus. Bearings such as bearing shownas 5668 are also located in the end enclosure 5602.

Referring now to end enclosure 5604, several openings are shown thereinwith other apparatus attached thereto. Preferably, three variable speeddrive motors, 5614, 5616 and 5618 are fixed to the end enclosure 5604and each motor is attached to corresponding shafts shown as 5670, 5672and 5674. A subassembly 5601 is mounted to end enclosure 5604 in adesired position and can pass ground beef into the tube 5622 directlyfrom a grinding apparatus without contacting atmospheric air.Preferably, all shafts, tubes, components and assemblies attached to endenclosures are sealed in a suitable and desired gas tight manner,thereby retaining any gas that may be contained within vessel 5624, atany suitable pressure.

Referring again to FIG. 187, three separate augers (two shown), depictedas 5678, 5680 and 5682 are preferably mounted in close proximity to eachother and with a member 5682 arranged above auger shown as 5676separating it from augers 5678 and 5680. Preferably, augers 5676, 5678and 5680 can be arranged in a horizontally disposed and parallelposition. Auger 5676 is attached to drive motor 5614, auger 5678 isattached to drive motor 5616 and auger 5680 is attached to drive motor5618. The end sections of each auger 5676, 5678 and 5674 are arrangedwith shafts and each shaft end mates with bearings located in endenclosures 5602 and 5604. Drive motors 5614, 5616 and 5618 are arrangedto drive the corresponding augers at variable rotating speeds in anychosen direction, either clockwise or counterclockwise, as may beselected according to any desired direction and at any suitable speedthat will enable optimized mixing of the ground meats processed in tube5622. Alternatively one or any number of augers may be located in tube5622 to provide the most optimized mixing therein.

Referring again to FIG. 187, sub-assembly 5601 is attached to endenclosure 5604 and can be operated to grind beef and inject the groundbeef directly into tube 5622. In this way, ground meat can becontinuously provided into tube 5622, at any suitable rate within thecapacity of the apparatus. Referring now to FIG. 190, the ground beefthat flows into tube 5622 can be arranged to fall directly onto butcentrally and between the center lines of augers 5678 and 5680.Preferably, augers 5678 and 5680 can be arranged to rotate in oppositedirections. Direction of rotation of auger 5678 can be in a clock-wisedirection and auger 5680 can be rotated in a counter clockwisedirection. In this way, the ground beef can be carried by augers 5678and 5680 toward end enclosure 5604 and away from end enclosure 5604.Member 5682 is arranged to allow containment of the ground beef betweenits upper faces and augers 5678 and 5680 for a brief period such that asaugers rotate the ground beef is carried toward the end enclosure 5604.As augers 5678 and 5680 rotate the ground beef will then drop andcontact tube 5622. Preferably, tube 5622 can be arranged to rotate at asuitable speed, of between about 100 rpm or less and about 500 rpm ormore, such that centrifugal force will hold the ground beef against theinternal surface of tube 5622. When tube 5622 has rotated byapproximately one half of one revolution and the ground beef is carriedto an upper location and above augers 5678 and 5680, a scraper 5625 canbe provided to remove the ground beef from contact with tube 5622. Thescraper 5625 can be arranged to cause the ground beef to be directedback onto augers 5678 and 5680. Auger 5676 can be driven in a directionthat will carry any ground beef, that it contacts, toward the endenclosure 5602. Preferably, the rotating speed of each auger can beadjusted as required. Preferably, auger 5676 can be arranged to have anextended length, that is longer than 5678 and 5680 such that 5676extension extends beyond 5678 and 5680 and into a tubular section, shownas 5722, with an internal diameter slightly larger than the externaldiameter of auger 5676. As shown in FIG. 187, auger 5676 can then bearranged to carry ground beef from within tube 5622 and through tubularsection 7522 at a desired rate. In this way the ground beef will becarried toward end 5602 by augers 5678 and 5680 and toward end 5604 by5676. The rotation of tube 5622 and its interaction with the scraper5625 will then provide further mixing fat and muscle content of theground beef. By independently adjusting the rotating speed of augers5676, 5678 and 5680 and also tube 5622, the period of time that theground beef is retained within the tube 5622 can be controlled to anoptimized period of time and thereby allow an efficient method ofblending. Preferably, after a suitable period of retention, the groundbeef will be transferred through tube 5642 and will then fall downwardlyinto tube 5724. Tube 5724 can be located directly above and connected toa suitable vane pump shown as 5726, which may include any suitable vanepump manufactured by Weiler & Company, Inc. Preferably, the ground beefcan be pumped at a known and controlled velocity by vane pump 5726 intotube 5728 which is connected directly thereto. Tube 5728 can beconnected to another measuring device 5730. In this way, ground beef canbe ground and injected into tube 5622, by sub-assembly 5601, and afterpassing through a first measuring device 5730, blended by augers beforepumping through a second measuring device 5730 located between tubesshown as 5728 and 5732. Ground beef can be conditioned and blended at aproduction rate limited only by the chosen size and capacity of theground beef conditioning and blending apparatus, which may be varied insize and capacity as required.

The conditioned and blended ground beef can thus be pumped through tube5732 at a desired and controlled temperature with a quantity of suitablegas such as carbon dioxide, dissolved in the ground beef to any desiredlevel of saturation. Vane pump 5726 can be provided with a variablespeed drive motor and arranged to pump ground beef at a controlledvelocity into other apparatus for subsequent blending with other groundbeef or chosen material and/or further processing.

In a preferred embodiment the conditioned ground beef may be exposed toa suitable beam of electrons by locating an electron beam generator andaccelerator such as may be manufactured by Titan-Scan Systems of 3033Science Park Road, San Diego, Calif. 92121. Preferably, the electronbeam generator may be located in such a manner that the suitable beam ofelectrons produced there with, is directed directly at and through astream of grinds while the grinds are passing through a tube such astube 5754 shown in FIG. 191. The cross-sectional profile of the tube maybe arranged to provide maximum exposure to the electron beam. In thisway the conditioned ground beef can be sterilized at any temperaturewhile maintaining a fresh and uncooked condition. Preferably, electronbeam sterilization is used on fresh ground beef which is in a low oxygenenvironment to prevent over-oxidation. In an alternative embodiment thestream of conditioned ground beef can be exposed to irradiation from asource of gamma rays.

Referring again to FIG. 191, a section of assembled tubes is detailed.The section of tubes includes a first tube 5744, a second tube 5746 anda third tube 5748 which are all joined at a confluence, 5750, to afourth tube 5754. The tubes and particularly the confluence may bemanufactured from any suitable plastics or stainless steel materials andmachined so as to ensure that any processed materials passingtherethrough, will not be subject to significant turbulence until afterpassing through the confluence 5750. Preferably, any number of two ormore tubes joined, at a confluence, to a single tube 5754, may bearranged to produce processed materials as may be desired. In apreferred configuration, a first processing machine (not shown), isarranged to deliver the processed material via tube 5744, a secondprocessing machine (not shown), is arranged to deliver the processedmaterial via tube 5746 and a third processing machine (not shown) isarranged to deliver the processed material via tube 5748. Preferably,the fat content of each stream of ground beef can be measured, by anysuitable measuring device such as that shown as 5730 in FIG. 195, andthe fat content will therefore be known. Preferably, the velocity ofeach stream of material can be adjusted by adjusting the speed ofseparate vane pumps arranged in such a manner so as to provide forvelocity adjustment. By adjusting the velocity of each stream ofprocessed material corresponding to the measured fat content containedtherein, delivered quantities of the processed material, can be adjustedsuch that when any two or more streams are combined together, theresultant fat content of the combined stream will be substantiallyconstant and as required. In this way, the known fat content of thecombined stream of processed material can be maintained to within anarrow range of variation. The variation may be within a range of notmore than +/−1% of the fat content of any item such as Item 1F.

Referring now to FIG. 192, a preferred embodiment including a group ofthree blending tubes 5756, 5758 and 5760 is shown, each tube beingsimilar in operation to tube 5622 shown in FIG. 187. Preferably, thegroup of three blending tubes are each assembled with an auger similarto as described above in association with the tube 5622 and auger 5676,5678 and 5680. Rollers 5762, 5764 and 5766 are arranged to engage andretain the blending tubes as shown. A pressure vessel 5768, is arrangedto accommodate the group of three blending tube assemblies such thatdrive wheels 5770 are engaged there with and as shown and can beactivated as required so as to rotate the blending tubes. Ground beefcan be provided into each blending tube by similar apparatus to thatdisclosed above with subassemblies 5601 of FIG. 188. In this way, threegrades of ground beef can be processed simultaneously in threecontinuous streams. Each of the continuous streams of conditioned groundbeef can be further processed if desired.

In a preferred embodiment, a plurality of processing machines arearranged to process material such as fine ground (or coarse ground)meat, such as beef grinds. Each of the processing machines may besimilar to the apparatus shown in FIG. 187. A total of three processingmachines can include a first machine, a second machine, and a thirdmachine, and can be arranged so that each processing machine can processa separate quantity of boneless beef. The first machine, may process aquantity of Item 1, the second machine, may process a quantity of Item 2and the third machine, may process a quantity of Item 3. The first,second and third machines will therefore produce first, second and thirdstreams of ground beef (processed material) that, after processing, willbe pumped, by separate vane pumps (for delivery as required), alongtubes shown as 5732 in FIG. 187.

Preferably, any number of one or more processing machines may bearranged so to provide any number of streams of processed material.Preferably, the streams of processed material may be combined and joinedtogether in any chosen configuration, to produce one or more subsequentstreams of processed material. Preferably, the velocity of each streamof material may be adjusted, so as to deliver a known and correspondingquantity of processed materials with any desired fat content asrequired. Preferably, the fat content and muscle content, of each streamof processed material can be continuously measured, as described herein,or in any other suitable manner. One or more streams of processedmaterials may be combined to produce a single stream of processedmaterial. By adjusting the velocity and consequent delivered quantity ofeach stream of material (before combining together into a resultantsingle stream) any quantity of any processed material, such as Item 1Fcan be produced to a substantially constant and precise specification.The combined stream of processed materials may be further processedthrough a grinder and/or through processing machines such as that shownin FIG. 187. Additionally, the streams of processed materials may bedirected through a tube that is exposed to sterilization such as byexposure to gamma irradiation, or any other suitable sterilizer whilecontained within the tube.

Subsequent to processing, the beef grinds or processed material can beretail or bulk packaged in any suitable manner, such as a substantiallyoxygen free modified atmosphere master package.

The packaging may be arranged to accommodate a variation in total volumeof the package such as an expansion or contraction in volume. Thepackage volume variation may occur as the temperature variation of thepackaged processed material. The volume variation may correspond to thetemperature variation as a result of any gases dissolved in theprocessed materials “boiling off” or again dissolving in directrelationship to the temperature variation. Accommodation of thevariation in package volume may be achieved by provision of a suitablysized, flexible, substantially gas barrier package.

Referring again to end enclosures 5602 and 5604 shown in FIG. 187,suitably located apertures shown as 5736, are provided therein so as toallow free movement of gas therethrough. The velocity of the gas canthen be controlled by blower 5648 and along a path through tube 5622,into the spaces shown as 5738 and back through space 5636. Preferably,the velocity and temperature and pressure of the gas can then arrangedat the most effective settings to control the temperature of the groundbeef and the rate of gas dissolving therein.

Referring now to FIG. 194 and particularly, end enclosure 5604, a membershown as 5738 is arranged to mate with member 5604 at a close contactingface shown as 5740. Members 5604 and 5738 are in contact at interface5740, and fixed relative to each other but not locked together. Member5738 can move relative to 5604 but is retained by interface 5740 andshafts shown as 5670 and 5674 (and 5672, which is not shown). Suitablebearing surfaces are provided between 5738 and 5604 and also between5738 and 5676, 5678 and 5680. Sub assembly 5601 is arranged so as to beremovable for cleaning purposes and plugs may be inserted into theconnecting apertures created by removing sub-assembly 5601. When 5601 isremoved and replaced with the plugs, member 5738 can be moved away fromtube 5622 by sliding along shafts 5676, 5678 and 5680 so as to provide aspace between member 5738 and the end rim of tube 5622. Preferably, suchan arrangement may be installed at either or both end enclosures of theapparatus in such a manner so as to facilitate effective cleaning ofapparatus after use. Other cleaning features may be incorporated intothe apparatus. Preferably, pressurized and heated water may be providedinside the apparatus with suitable sanitizing detergents in such amanner so as to facilitate an automatic cleaning when augers 5676, 5678and 5680 and tube 5622 are all rotated in common or opposing directionsand at suitable speeds. Alternatively or additionally high pressuresteam may be provided inside the apparatus to facilitate sterilizationand thorough cleaning of the internal surfaces of the apparatus.Draining/venting tubes such as 5742 can be provided with valves, at anysuitable and convenient location on the apparatus.

Lean Muscle and Fat Measuring Apparatus

A lean tissue and fat analyzer is an optional feature of the meatprocessing system. Referring now to FIG. 189, a cross sectional view ofthe conduit of FIG. 188 is shown as a square or rectangular tube 5730.Preferably, tube 5730 and tube 5702 are similar. Tube 5730 can bemanufactured from any suitable material which includes plastics as well.Preferably, two electrodes, shown as 5710 and 5712 are located onopposing internal sides of tube 5730 and attached to terminals.Electrode 5710 is attached to terminal 5714 and electrode 5712 isattached to terminal 5716. An electrical current can be arranged to flowthrough terminals 5714 and 5716 and into electrodes 5710 and 5712.Ground beef (ground meat) is shown as 5715 and in this way, willdirectly contact the electrodes as it passes through tube 5730. Theelectrical current can therefore pass through ground beef from electrode5712 and to electrode 5710. Electrical current will be affected by theresistance of the ground beef and this resistance will vary according tothe ratio of fat and muscle content of the ground beef and therefore theelectrical resistance can be measured. The variation in electricalresistance can be measured and such measurements can be converted andused to determine the ratio of fat and muscle contained in the groundbeef in a continuous process. Tube 5730 with terminals and electrodestogether include a measuring device shown as 5718. Preferably, themeasuring device may be installed, and used to measure the ground beeffat and muscle content ratio, at any convenient location as may berequired.

Meat Grinder Sub-Assembly

A meat grinder sub-assembly is an optional feature of the meatprocessing system. Several embodiment of a meat grinder have beenpreviously described. However, a meat grinder preferably for use withthe processing machine follows.

Referring now to FIG. 193, a meat grinder sub-assembly according to thepresent invention is shown. The sub-assembly includes a pressure vessel5684, with an entry port 5686 at an upper location and an exit port 5688at a lower location. A horizontally disposed and tapered auger 5690 islocated in a lower portion of vessel 5684 and arranged with a shaft 5692that can be attached directly to a suitable variable speed driver.Preferably, the tapered auger is suitably profiled and is fitted withpassageways therein to allow any suitable gas to be injectedtherethrough. A meat grinding apparatus is attached directly to theentry port 5686 and can be disconnected therefrom to provide access forcleaning as required. Boneless meat portions can be processed by grinder5694 to produce grinds which are then transferred directly into vessel5684 in a continuous stream. Preferably, the cross-sectional profile ofvessel 5684 is circular and a valve member 5696 is arranged to mate witha valve seat 5698, which is located between the entry port 5686 and theauger 5690, to provide a gas tight seal when required. Valve member 5696can be opened and closed by valve stem 5697 as required and arranged toautomatically close as required for any reason. Ground beef that istransferred into vessel 5684 can contact auger 5690. Preferably, anysuitable gas at any suitable pressure can be injected into vessel 5684through ports 5700 and/or 5702. Each port such as 5702 and 5700 isfitted with suitable valve and pressure regulator. As desired, gas canbe injected into a port such as port 5702 and allowed to exit through aport such as 5700. Pressure regulators maintain a desired gas at anysuitable pressure in the vessel 5684. In this way, the continuous streamof ground beef can be transferred through the vessel 5684 by auger 5690at a desired rate and pressure. As the ground beef is transferredthrough vessel 5684 by tapered auger 5690, the ground beef is compressedand extruded through a restriction as shown, so as to exclude gas andproduce a substantially continuous flow of ground beef without gasbubbles contained therein. In this way the compressed ground beef canprovide an effective gas tight sealing between vessel 5684 and vessel5624 of FIG. 187. The continuous flow of ground beef is passed through atube section 5702 at a desired and controlled rate. After passingthrough tube 5702 the ground beef passes through the exit port 5688 andcan be directed into any suitable container such as tube 5622 shown inFIG. 187. If desired, a secondary grinder may be interposed between thevessel 5684 and a valve 5706. Valve 5706 is provided at the exit port5688 and can be arranged with an automatic actuator to open and close ata remote distance as may be required for any reason. When in a closedposition valve 5706 can seal the exit port 5688 in a gas tight manner.As the ground beef passes through tube section 5702, the fat and musclecontent of the ground beef can be measured. The measuring device mayinclude the passing of an electric current through the ground meat as itpasses through the section 5702. Preferably, the electrical resistanceis measured and a muscle and fat concentration can be obtained.

Meat Pre-Conditioning System

Referring now to FIGS. 196-197, a plan view and a side elevation view ofan apparatus designed to slice meat while conditioning in an oxygen freeenvironment is shown. The apparatus is shown in diagrammatic form andincludes a continuous conveyor 5100, with a driver mounted to a rigidframe (not shown) and horizontally disposed to allow horizontal motionin a machine direction in intermittent or continuous movement. Theconveyor is fitted with two corresponding and vertically opposed pairsof pressure chambers includes an upper chamber 5102 with a correspondinglower chamber 5104 and another upper chamber 5106 with a correspondinglower chamber 5108. An enclosed gassing tunnel 5118 is arranged toenclose the upper section of the conveyor 5100 with a gassing port 5112affixed thereto to provide any suitable gas, such as nitrogen gas orcarbon dioxide, into the tunnel 5118.

Referring now to upper chamber 5102 and corresponding lower chamber 5104the opposing chambers are arranged so as to open and close. Upperchamber 5102 is mounted to a driver (not shown) to provide elevating,lowering and clamping apparatus. Lower chamber 5104 is also mounted to aseparate driver (not shown) to provide elevating, lowering and clamping.Chambers 5102 and 5104 can be closed together by moving in opposingdirections so as to contact each other along a path around the perimeterof openings. In this way a single chamber is so arranged in a mannerthat is airtight and sealed from external atmosphere. An evacuation port5114 and a gas port 5116 are provided so as to allow evacuation and gasflushing of the closed chamber. As shown in FIG. 196 two separatepressure chamber assemblies are arranged such that conveyor 5100 passesthrough both chamber assemblies. Trays with sliced beef or other meatprimal, placed therein, are located into carrier plates in conveyor5100. The primals are sliced in a suitable manner and can then be openedso as to expose the multiple surfaces of the slices immediately prior toentry into enclosed tunnel 5118. Enclosed tunnel 5118 is arranged so asto substantially exclude atmospheric oxygen gas by flushing othersuitable gases therein. The trays with sliced primal 5122 are located incarrier plates and progressively move through enclosed tunnel 5118 untileach tray with primal is located directly between an upper chamber 5102and lower chamber 5104. The upper and lower chambers close together andaround the sliced primal 5122 in an airtight and sealed manner.Substantially all air is evacuated from the chambers and a suitable gas,including carbon dioxide, is injected through port 5116. The suitablegas pressure can be increased to any suitable pressure as desired. Theprimal 5122 can be retained in the pressure chambers for a desirableperiod of time so as to cause sufficient carbon dioxide gas to dissolvein the oils and water contained in the primal 5122. After the primal5122 has been exposed to the high pressure carbon dioxide gas for asuitable period of time, the pressure chambers open and allow conveyor5100 to carry sliced primal 5122 in tray, forward in machine directionand through the enclosed tunnel 5118. A second pressure chamber assemblymay also be closed around the sliced primal 5122 in tray. Any suitablegas at any suitable pressure can be provided in the second enclosedchamber. Second chamber includes an evacuation port 5115 and a gassingport 5117. The sliced primal 5122 in tray is intermittently carriedthrough the tunnel 5118 until it emerges at the exit end of the tunnel.

In this way, rapid formation of oxymyoglobin is inhibited when theprimal 5122 is exposed to ambient atmosphere.

Plant Layout

Having described meat grinding systems and ancillary equipment, it isappropriate to describe the integration of equipment to form a wholeproduction facility for processing and packaging meats.

Referring now to FIG. 198, a plan view of a preferred production plantlayout is shown, including ground meat processing, blending equipmentand retail packaging plant. The equipment shown in FIG. 198 isrepresented by diagrammatic sketches and is integrated such that groundbeef processed by the equipment shown can be transferred directly fromgrinders 6400, 6402 and 6404 into oxygen free vessels shown as 6408,6410 and 6412, respectively.

The chart set out below provides a list of equipment shown in FIG. 198.ID Item 6400 Grinder 6402 Grinder 6404 Grinder 6406 Grinder (Fine) 6408Vessel + Mix 6410 Vessel + Mix 6412 Vessel + Mix 6414 Vessel/Hopper 6416Vessel/Hopper 6418 Vessel/Hopper 6420 Positive displ. pump 6422 Positivedispl. pump 6424 Positive displ. pump 6426 Positive displ. pump 6428Measure fat/lean 6430 Measure fat/lean 6432 Measure fat/lean 6434Continuous blending 6436 Control Panel 6438 Valve (diversion) 6440Elevator 6442 Elevator 6444 Discharge Ports 6446 Discharge Ports 6448Discharge Port 6450 Magazine 6452 Gas Exchange 6454 Tray Welding 6456Grinds Portioning machine 6458 RT 1800 Packaging Machine 6460 HorizontalVacuum

Boneless beef with a suitable fat/lean composition is loaded intogrinders 6400, 6402, 6404. Ground beef is produced by grinders 6400,6402 and 6404 and transferred directly into enclosed vessels 6408, 6410and 6412 that are otherwise filled with a suitable gas at a suitablepressure.

Vessels 6408, 6410 and 6412 can be fitted with blending apparatus so asto blend grinds therein. Positive displacement pumps 6420, 6422 and 6424pump quantities of grinds, in three respectively separate streams fromvessels 6408, 6410 and 6412 directly into continuous blender CB. Thequantity of grinds pumped by the positive displacement pumps in theseparate streams is controlled and dictated by the measured fat and leancontent of each stream of grinds. Fat and lean content of each stream ofgrinds is measured by measuring devices shown as 6428, 6430 and 6432.Continuous blender 6434 terminates at positive displacement pump 6424and blended grinds are transferred directly from 6434 into 6424. Pump6424 can transfer the blended grinds in a single continuous stream intoeither vessel 6418 or vessel 6416.

Grinds can be stored in vessels 6416 and 6418 as may be required. Thegrinding, pumping, measuring and blending apparatus can be arranged soas to produce a single stream of grinds by combining three separatestreams into a single stream in continuous blender 6434. The singlecontinuous stream of blended grinds can be produced according to aspecification such as 85% lean and 15% fat. Alternatively, single streamof blended grinds can be produced according to any other desiredspecification such as 90% lean and 10% fat. In this way two separatequantities of specified grinds can be stored with one in each of vessels6416 and 6418. For example, a quantity of 85% lean and 15% fat grindscan be stored in vessel 6416 and a quantity of 90% lean and 10% fatgrinds can be stored in vessel 6416. Suitable positive displacementpumps can be arranged to transfer specified quantities of grinds fromeither or both vessels 6416 and 6418 for separate or combined grindingin a grinder such as is shown as 6406 is FIG. 198. Any suitable numberof pumps can be arranged to transfer grinds from either of the vessels6416 and 6418 for further blending and/or grinding and subsequent retailpackaging in packaging machine shown as 6458. If required suitableblending equipment can be provided for blending of any suitable numberof additional pairs of streams of grinds, in selected quantities, afterpumping from vessels 6416 and 6418 to produce specified quantities ofblended grinds that can then be fine ground prior to retail packaging.

In this way, ground meat can be processed and packaged while beingcontained within a series of vessels and tubes that are filled withground meat and suitable gas that substantially excludes oxygen and anyother undesirable gas and/or material. Therefore, formation ofoxymyoglobin on substantially all freshly cut meat surfaces can beinhibited until after packaging and immediately prior to retail displayor other desired use.

Referring now to FIG. 199, a plan view of another preferred productionplant layout is detailed including production and packaging equipment.

A preferred layout includes items of equipment in the table below andidentified by a reference numeral. TABLE 3 Item # Production EquipmentPackaging equipment 5900 Grinding machine 5960 Chub/vacuum packagingmachine 5902 Grinding machine 5930, Ground beef 5932, portioningmachines 5934 5904 Grinding machine 5940, Over wrapping 5938, packaging5936 machines 5906 Ground beef processing machine 5954, Foam tray 5956,erecting machines 5958 5908 Ground beef processing machine 5924,Conveyor belts 5926, 5928 5910 Ground beef processing machine 5922Ground beef processing machine 5942 Gas blower with heat exchanger. 5912Ground beef Injector 5914 Ground beef Injector 5916 Ground beef Injector5944 Ground beef Injector 5946 Vane pump 5948 Vane pump 5950 Vane pump5952 Vane pump 5918 Multi-tube combining die 5920 Electron beamsterilizer and/or grinder

Preferably, the equipment shown in FIG. 199, and listed above, isarranged to continuously produce and retail package, case ready groundmeats. Quantities of specified boneless beef raw materials are processedby grinding machines 5900, 5902 and 5904 to produce grinds that aretransferred directly into ground beef processing machines 5906, 5908 and5910 via corresponding injector machines 5912, 5914 and 5916. Eachgrinder processes a quantity of specified boneless beef raw materialseach of which may be selected from the following table of raw materialsItem 1 through Item 5. TABLE 4 Muscle Fat Item Tissue Tissue 1 93%  7% 290% 10% 3 75% 25% 4 65% 35% 5 50% 50%

Equipment shown as vessels 5906, 5908 and 5910 is arranged to processgrinds as above described apparatus shown in FIG. 187. Grinds areinjected into vessels from the grinders 5900, 5902 and 5904 by injectors5912, 5914 and 5916 which are arranged to operate as the above describedapparatus shown in FIG. 193. Conditioned grinds are transferred in asingle continuous stream from each vessel, by a pump from vessels intotransfer tubes which are then combined at confluence 5918 into a singletube. Confluence 5918 includes a manifold generally as the abovedescribed apparatus shown in FIG. 191.

Preferably, the fat content of the continuous streams of grinds iscontinuously measured by measuring devices as the above describedapparatus shown in FIG. 194. Preferably, the fat content of the grindscan be continuously measured before injection into the vessels andimmediately after transfer from the vessels and into the transfer tubes.Preferably by measuring the fat content and automatically adjusting theflow rate of each stream of grinds, directly and according to themeasured fat content, prior to combining the streams of grinds, acombined stream of grinds with consistent fat content can be produced.The combined stream is then transferred via a tube into a single grindershown as 5920. An electron beam generator of suitable capacity may beintegrated such that the combined stream of grinds passes therethroughprior to injection directly into vessel 5922. Vessel 5922 may bearranged to process grinds as the above described apparatus shown inFIG. 187. A single stream of conditioned grinds is then transferred intoa single tube that is divided into four separate streams of grinds.

Still referring to FIG. 199, the preferred plant layout includes fourpackaging systems and a single supply stream of grinds is transferred toeach of the packaging systems. Preferably, one stream to “chub/vacuum”packaging machine. Preferably, apparatus constructed according to thepresent invention includes three packaging machines 5924, 5926, and5928, and a single stream of grinds to each of three portioningmachines, shown as 5930, 5932, and 5934, respectively. Portions ofgrinds are then retail packaged by automatic loading into trays whichare then over wrapped by packaging machines shown as 5936, 5938, and5940. While, an embodiment has been described and shown to include threeprocessing trains, any suitable number of processing trains may be usedin accordance with the present invention, which may include more or lessthan the three trains herein described.

The equipment as described herein may be arranged to automaticallyproduce any quantities of coarse or fine grinds according to anyspecifications. The following table shows the specified muscle and fattissue content of three types of fine beef grinds. TABLE 5 Muscle FatItem Tissue Tissue 1F 90% 10% 2F 75% 25% 3F 65% 35%

Equipment as described herein may be arranged to grind, measure,condition, blend, process and package specified portions of grindsaccording to any suitable size by automatically computer controller. Thecomputer controller may continuously provide production informationincluding such data as the total fat and muscle tissue content of eachand all streams of grinds during the processing. In this way, a methodto improve efficiency and reduce total losses is provided by producinggrinds to meet precise specifications according to, for example, thelist of fine beef grinds shown above.

Plant Layout

Referring now to FIGS. 200 and 201, another preferred production plantlayout including ground meat processing and blending equipment and apreferred CAP retail packaging plant layout including packagingequipment is shown. The equipment shown in FIG. 200-201 is integratedsuch that ground beef processed by equipment shown in FIG. 200 ispackaged in packaging that is processed by equipment shown in FIG. 201.The present invention provides for a method of grinding meats directlyinto an oxygen free vessel or hopper and then blend and process theground meat as described herein. The present invention also provides amethod of saturating the liquids, water and oils in the ground meatswith a suitable gas or substance such as carbon dioxide, provided at asuitable pressure, to such a level that when removed from the processingequipment the ground meat will emit a suitable gas such as carbondioxide.

Items of equipment shown in FIG. 200-201 that are identified by lettersand/or numbers are listed in the following table set out below: Item #Production Equipment Packaging equipment 6006 Conveyor (with variablespeed 6122 Magazine control) 6008 Conveyor (with variable speed 6124Magazine control) 6010 Conveyor (with variable speed 6126 Magazinecontrol) 6018 Conveyor (with variable speed 6128 Tray material control)evacuation & gassing 6020 Conveyor (with variable speed 6130 Traymaterial control) evacuation & gassing 6022 Conveyor (with variablespeed 6132 Tray material control) evacuation & gassing 6034 Conveyor(with variable speed 6134 Tray flap erection & control) welding 6036Conveyor (with variable speed 6136 Tray flap erection & control) welding6030 Ultra violet sterilization 6138 Tray flap erection & equipmentwelding 6032 Ultra violet sterilization 6140 Conveyor equipment 6038Grinding machine 6142 Conveyor 6040 Grinding machine 6144 Conveyor 6100Grinding machine 6116 Ground beef portioning machine 6104 Grindingmachine 6118 Ground beef portioning machine 6108 Grinding machine 6120Ground beef portioning machine 6046 Tube connection 6146 Conveyor 6050Tube connection 6148 Conveyor 6048 Ground beef hopper 6150 Conveyor 6052Ground beef hopper 6000 Over wrapping packaging machines 6058 Groundbeef hopper 6002 Over wrapping packaging machines 6064 Ground beefhopper 6004 Over wrapping packaging machines 6056 Statiflo blender 6062Statiflo blender 6090 Statiflo blender 6092 Statiflo blender 6094Statiflo blender 6096 Gas injection ports. 6054 Positive displacementpump 6060 Positive displacement pump 6066 Positive displacement pump6068 Positive displacement pump 6070 Positive displacement pump 6072Positive displacement pump 6074 Positive displacement pump 6076 Positivedisplacement pump 6078 Epsilon GMS-40 6084 Epsilon GMS-40 6080 EpsilonGMS-40 6086 Epsilon GMS-40 6082 Epsilon GMS-40 6088 Epsilon GMS-40Electron beam sterilizer and/or grinder

The equipment shown in FIG. 200-201 is listed above and is arranged toautomatically and continuously produce selected grades of retailpackaged, case ready ground meats. The ground meats may includequantities of muscle and fat tissues such as shown in the followingchart, where item 1F includes ground meat with about 90% muscle tissueand about 10% fat tissue, with a muscle to fat tissue variation withinabout +/−0.2%. The packaging equipment shown in FIG. 201 can be arrangedso that the packaging machine 6000 will produce CAP case ready packagescontaining ground meats according to a specification equivalent to item1F. Similarly, packaging machine 6002 can produce CAP case readypackages containing ground meats according to a specification equivalentto item 2F and packaging machine 6004 can produce CAP case readypackages containing ground meats according to a specification equivalentto item 3F in TABLE 7. TABLE 7 Muscle Fat Muscle/Fat Item Tissue TissueTissue Variation 1F 90% 10% +/−0.2% muscle content 2F 85% 15% +/−0.2%muscle content 3F 80% 20% +/−0.2% muscle content

Referring again to FIG. 200, variable speed conveyors 6006, 6008 and6010 are preferably arranged in close and parallel proximity such thateach conveyor can carry specified quantities of selected boneless beef.In this way conveyor 6006 can be arranged to carry specified quantitiesof raw material, which may be boneless beef selected from the chartshown below, in a direction indicated by arrow 6012, conveyor 6008 canbe arranged to carry specified quantities of selected boneless beef in adirection indicated by arrow 6014 and conveyor 6010 can be arranged tocarry specified quantities of selected boneless beef in a directionindicated by arrow 6016. The specified quantities of selected bonelessbeef can be varied between the conveyors marked 6006, 6008 and 6010 suchthat 6006 carries selected boneless beef shown as 2X, in TABLE 8,conveyor 6008 carries selected boneless beef shown as 3X and conveyor6010 also carries the selected boneless beef shown as 3X.

Preferably, variable speed conveyors 6018, 6020 and 6022 are arranged inclose and parallel proximity such that each conveyor can carry specifiedquantities of selected boneless beef. In this way conveyor 6018 can bearranged to carry specified quantities of raw material, which may beboneless beef selected from TABLE 8, in a direction indicated by arrow6024, conveyor 6020 can be arranged to carry specified quantities ofselected boneless beef in a direction indicated by arrow 6026 andconveyor 6022 can be arranged to carry specified quantities of selectedboneless beef in a direction indicated by arrow 6028. The specifiedquantities of selected boneless beef can be varied between the conveyorsmarked 6018, 6020 and 6022 such that conveyor 6018 carries boneless beefshown as 1X in TABLE 8, conveyor 6020 carries boneless beef also shownas 1X and conveyor 6022 carries boneless beef shown as 2X. TABLE 8Muscle Fat Item Tissue Tissue Muscle/Fat Tissue Variation 1X 99% 1%+1%/−3% muscle content 2X 93% 7% +/−3% muscle content 3X 75% 25%  +/−3%muscle content

Preferably, the variable speed conveyors 6006, 6008 and 6010 can bearranged in close and parallel proximity and located inside an ultraviolet light (UV) tunnel shown as 6030 in FIG. 200. Tunnel 6030 can bearranged so as to expose any of the selected boneless beef to sufficientUV light so as to substantially sterilize the surfaces of the bonelessbeef. A suitable device of turning and/or rotating the boneless beef canbe provided in the tunnel, so as to ensure that substantially allexternal surfaces of the boneless beef are exposed to the UV light toensure the sterilization of the surfaces. Similarly, the variable speedconveyors 6018, 6020 and 6022 can be arranged in close and parallelproximity and located inside an ultra violet light (UV) tunnel shown as6032 in FIG. 200. Tunnel 6032 can be arranged so as to expose any of theselected boneless beef to sufficient UV light so as to substantiallysterilize the surfaces of the boneless beef. A suitable method ofturning and/or rotating the boneless beef can be provided in the tunnel,so as to ensure that substantially all external surfaces of the bonelessbeef are exposed to UV light to ensure sterilization of surfaces.

Preferably, the variable speed conveyors 6006, 6008, 6010, 6018, 6020,and 6022 can be provided with independent drivers and arranged to passthrough a tunnel with a device to independently measure the fat andmuscle content of the boneless beef carried on each individual andseparate conveyor. Any suitable method of measuring the fat and musclecontent of the boneless beef may be integrated with the conveyors 6006,6008, 6010, 6018, 6020, and 6022 so as to provide a method of separateand continuous measurement of the fat and muscle content of the bonelessbeef separately carried on each conveyor. Preferably, the variable speedconveyors 6006, 6008, and 6010 can be arranged to converge and depositthe boneless beef, carried by each independent conveyor onto aconveniently located secondary conveyor shown as 6034 in FIG. 200.Similarly, the variable speed conveyors 6018, 6020, and 6022 can bearranged to converge and deposit the boneless beef, carried by eachindependent conveyor onto a conveniently located secondary conveyorshown as 6036 in FIG. 200. Preferably, the speed of each conveyor can bevaried in direct relationship to the variation of measured fat andmuscle content of the boneless beef carried by each conveyor.

Preferably, the length of the variable speed conveyors 6006, 6008, 6010,6018, 6020, and 6022 can be extended so as to allow operators, such ascarcass disassembly workers, to deposit the boneless beef raw materialthereon immediately after disassembly and separation from an animalcarcass source of the boneless beef. Furthermore, the carcassdisassembly workers can, for example adjust the fat content of bonelessbeef that is deposited onto each of the conveyors 6006, 6008, 6010,6018, 6020, and 6022 according to requirements. More specifically, if itis determined by the fat measuring device that a reduced quantity of fatand an increased relative quantity of muscle (lean) tissue is requiredon any particular conveyor, this can be accommodated. Conversely, if itis required to deposit an increased relative quantity of muscle tissueonto any particular conveyor, this also, can be accommodated. In thisway, the fat and lean content of the boneless beef that is depositedonto each of the individual conveyors can be adjusted to suitrequirements which can be determined by the fat content measuring methodthrough which each of the conveyors can be arranged to pass. Preferably,boneless beef can be deposited onto variable speed conveyors 6006, 6008,and 6010 according to requirements and by varying the speed of eachconveyor and therefore the quantity of boneless beef carried anddeposited onto conveyor 6034, a combined stream of boneless beefincluding fat and muscle tissue with a desired and constant relativeratio can be produced and carried on the conveyor 6034. Similarly, withvariable speed conveyors 6018, 6020, 6022, boneless beef can bedeposited onto each conveyor according to requirements and by varyingthe speed of each conveyor and therefore the quantity of boneless beefcarried and deposited onto conveyor 6036, a combined stream of bonelessbeef, carried on conveyor 6036 and including fat and muscle tissue witha desired and constant relative ratio, can be produced and carried onthe conveyor 6036.

Referring again to FIG. 200 and in particular to conveyor 6034, it canbe seen that boneless beef carried on 6034 will be carried and depositedinto meat grinder 6038. Similarly, it can be seen that boneless beefcarried on conveyor 6036 will be carried and deposited into meat grinder6040. By adjusting the ratio of fat and muscle content of boneless beefcarried on each conveyor 6006, 6008, and 6010 and adjusting the speedand therefore the volume of boneless beef carried on each conveyor, asingle stream, indicated as stream 6042 in FIG. 201, of boneless beefincluding fat and muscle tissue of a desired ratio can be provided andcarried forward on conveyor 6034. Similarly, by adjusting the ratio offat and muscle content of boneless beef carried on each conveyor 6018,6020, 6022 and adjusting the speed and therefore the volume of bonelessbeef carried on each conveyor 6018, 6020, and 6022, a single stream,indicated as stream 6044 in FIG. 201, of boneless beef including fat andmuscle tissue of a desired ratio can be provided and carried forward onconveyor 6036.

Preferably, in this way, boneless beef stream 6042 may include bonelessbeef with a fat and muscle content of about 95% lean muscle and about 5%fat with a fat content variation of about +/−0.3%. Preferably, bonelessbeef stream 6044 may include boneless beef with a fat and muscle contentof about 80% lean muscle and about 20% fat with a fat content variationof about +/−0.3%.

Boneless beef stream 6042 is carried forward by conveyor 6034 anddeposited into grinder 6038. Conveyor 6034 and grinder 6038 may beenclosed inside a substantially sealed outer covering with a suitablegas such as nitrogen contained therein in such a manner so as tosubstantially exclude ambient air from presence therein. The bonelessbeef carried in stream 6042 is ground in the grinder 6038 andtransferred through tube 6046 and into hopper 6048. It can also be seenthat the boneless beef stream 6044 is carried forward by conveyor 6036and deposited into grinder 6040. The conveyor 6036 and grinder 6040 mayalso be enclosed inside a substantially sealed outer covering with asuitable gas such as nitrogen contained therein in such a manner so asto substantially exclude ambient air from presence therein. The bonelessbeef carried in 6044 is ground in grinder 6040 and transferred throughtube 6050 and into hopper 6052.

Stream 6042 of ground beef is then transferred by a pump, such as apositive displacement pump 6054, from hopper 6048 into and throughstatic blending tube 6056 and into hopper 6058. Stream 6044 of groundbeef is then transferred by a pump, such as a positive displacement pump6060, from hopper 6052 into and through static blending tube 6062 andinto hopper 6064. Preferably, positive displacement pumps 6054 and 6060can be fitted with variable speed drivers Hoppers 6058 and 6064 can besubstantially filled with a suitable gas such as carbon dioxide or anyother suitable substance, and both hoppers 6054 and 6060 are arranged tohave an adequate capacity to accommodate any quantity variations innormal production of boneless beef that may result from any variablerequirement.

Hopper 6058 is connected with three positive displacement pumps shown as6066, 6068 and 6070. Preferably, any number of pumps may be provided andconnected to hopper 6058. Similarly, hopper 6064 is connected with threepositive displacement pumps shown as 6072, 6074 and 6076. Preferably,any number of pumps may be provided and connected to hopper 6064.Preferably, each of the positive displacement pumps shown as 6066, 6068and 6070 can be fitted with suitable, independently controlled, variablespeed drivers such that any required quantity of ground boneless beefcontained in hopper 6058 can be pumped therefrom at a desired velocity,and through a measuring device, such as the Epsilon GMS-40 shown as6078, 6080 and 6082. Similarly, each of the positive displacement pumpsshown as 6072, 6074 and 6076 can preferably be fitted with suitableindependently controlled, variable speed drivers such that any requiredquantity of ground boneless beef contained in hopper 6064 can be pumpedtherefrom and through a measuring device, such as the Epsilon GMS-40shown as 6084, 6086 and 6088.

The Epsilon GMS-40-40 Meat Analyzer is a fat measuring device and iscommercially available from Epsilon Industrial, 2215 Grand AvenueParkway, Austin, Tex. 78728. Specifications for the GMS-40 are availablefrom this supplier and information is also available from their web siteat www.epsilon-gms.com. While this component is specified herein, othersuitable fat measuring devices can be used as an alternate for fatand/or muscle content measurement.

As can be seen in FIG. 200, Epsilon GMS-40 measuring devices shown as6078 and 6084 are preferably attached directly to junction box X,Epsilon GMS-40 measuring devices shown as 6080 and 6086 are preferablyattached directly to junction box Y and Epsilon GMS-40 measuring devicesshown as 6082 and 6088 are attached directly to junction box Z. Suitablysized tubes connect pumps directly to corresponding Epsilon measuringdevices as shown. The fat content of ground beef that is pumped by pump6066 through the connecting tube and directly through Epsilon GMS-40measuring device 6078, is measured by device 6078. The fat content ofground beef that is pumped by pump 6072 through the connecting tube anddirectly through Epsilon GMS-40 measuring device 6084, is measured bydevice 6084. The ratio and percentage quantity of fat in each separatestream of ground beef pumped by pumps 6066 and 6072 can therefore bemeasured and compared and the pumping rate of pumps 6066 and 6072 can beautomatically adjusted according to the respective fat content of eachstream of ground beef so as to provide a single stream of ground beef,after combining in junction box X, with a desired fat content. In thisway selected quantities of boneless ground beef can be pumped directlyfrom hopper 6058, containing ground beef from stream 6042 and hopper6064, containing ground beef from stream 6044, by pumps 6066 and 6072respectively and through Epsilon GMS-40 measuring devices shown as 6078and 6084 into junction box X. Similarly, selected quantities of bonelessground beef can be pumped directly from hopper 6058, containing groundbeef from stream 6042 and hopper 6064, containing ground beef fromstream 6044, by pumps 6068 and 6074 respectively and through EpsilonGMS-40 measuring devices shown as 6080 and 6086 into junction box Y.Preferably, selected quantities of boneless ground beef can be pumpeddirectly from hopper 6058, containing ground beef from stream 6042 andhopper 6064, containing ground beef from stream 6044, by pumps 6070 and6076 respectively and through Epsilon GMS-40 measuring devices shown as6082 and 6088 into junction box Z.

Preferably, selected quantities of ground meat from stream 6042 andstream 6044 can be combined in junction boxes X, Y and Z. By varying thepumping rate of variable speed positive displacement pumps 6066 and6068, a selected blend of ground beef, with a pre-determined and knownratio of fat to lean muscle tissue, can be pumped into junction box X.The fat content of the selected blend of ground beef pumped intojunction box X may be, for example, about 10%+/−about 0.3%.Alternatively, the fat content of the selected blend pumped intojunction box Y may be, for example, about 15%+/−0.3% and the fat contentof the selected blend pumped into junction box Z may be, for example,about 17%+/−about 0.3%. By processing ground meats in this way, the fatcontent of any given production quantity of selected ground beef can becontrolled within a narrow margin of variation, such as about +/−about0.3% and the muscle and fat content selected as desired by adjusting thefat content of raw materials that are deposited onto conveyors 6006,6008, 6010, 6018, and 6020 accordingly. Furthermore, the energy requiredto blend the ground beef in the methods described herein is much lessthan is typically required to produce ground meats using currentlycommon industry practice.

The selected ground beef blend that is pumped into junction box X by wayof two streams from pumps 6066 and 6072 is then transferred throughblender 6090. The selected ground beef blend that is pumped intojunction box Y by way of two streams from pumps 6068 and 6074 is thentransferred through blender 6092. The selected ground beef blend that ispumped into junction box Z by way of two streams from pumps 6070 and6076 is then transferred through blender shown as 6094.

Blender 6056, 6062, 6092, and 6094 are all conveniently arranged withgas injection ports shown as 6096. Preferably, gas injection ports 6096are arranged to provide suitable gas, such as carbon dioxide, intoblenders in such a way as to ensure that all ground meat that is pumpedthrough the blenders is exposed to gas as desired and to an extent thatwill, for example, ensure that ground meat is saturated with dissolvedsuitable gas as required. Blenders 6056, 6062, 6090, 6092, and 6094 mayinclude suitably sized continuous static mixing equipment such as may besupplied by Statiflo International, Macclesfield, Cheshire, UK.Preferably, any continuous blender may be integrated and located whereindicated in FIG. 200 by blender reference numerals 6056, 6062, 6090,6092 and 6094 or in any desired configuration that will ensure blendingof ground meats as required.

The process described in association with FIG. 200-201 shows acombination of equipment that is configured to preferably produce afirst 6042 and a second 6044 stream of ground meat. Stream 6042 andstream 6044 are provided by measuring the fat content of two pair ofthree streams of boneless meat where streams 6012, 6014 and 6016converge into a first stream 6042 and where streams 6024, 6026, and 6028converge into a second stream 6044.

Preferably, the fat and muscle (lean) meat content of stream 6042 isdetermined by the following factors: The total quantity of boneless meatdeposited onto the conveyors that include the streams 6012, 6014, and6016 and the fat and muscle content of the boneless meat. The velocityof the streams 6012, 6014, and 6016.

Correspondingly, the fat and muscle (lean) meat content of stream 6044is determined by the following factors: The total quantity of bonelessmeat deposited onto the conveyors that include the streams 6024, 6026and 6028 and the fat and muscle content of the boneless meat. Thevelocity of the streams 6024, 6026 and 6028.

The fat and lean content of streams 6042 and 6044 can be determined byadjusting the velocity of streams 6012, 6014, 6016, 6024 and 6028 andthe fat content of the boneless meat provided into streams 6012, 6014,6016, 6026 and 6028.

Referring now to FIG. 200, streams 6098, 6102 and 6106 are shown to beconnected directly to meat grinders 6100, 6104 and 6108. Grinders 6100,6104 and 6108 are arranged to fine grind the corresponding stream ofground meat and transfer directly into a corresponding portioningapparatus. Grinder 6100 is arranged to fine grind ground meat in stream6098 and transfer the stream of fine ground meat directly intoportioning apparatus. Grinder 6104 is arranged to fine grind ground meatin stream 6102 and transfer the stream of fine ground meat directly intoportioning apparatus 6118. Grinder 6108 is arranged to fine grind groundmeat in stream 6106 and transfer the stream of fine ground meat directlyinto portioning apparatus 6120. Preferably, any suitable variable speeddriver may be integrated into equipment shown in FIG. 200 and may becontrolled by a central processing computer.

The fat and muscle (lean) content of the stream of ground meat that isshown as stream 6098 and which is delivered to grinder 6100, isdetermined by the fat and lean content of a quantity of ground meat fromboth stream 6042 via pump 6070 and an additional quantity of ground meatfrom stream 6044 via pump 6076. The fat and muscle (lean) content of thestream of ground meat that is shown as stream 6098 is also determined bythe velocity (and quantity of ground meat pumped therethrough) of theground meat stream pumped into junction box Z by pump 6070 and theground meat stream pumped into junction box Z by pump 6076. By adjustingthe speed of pumps 6070 and 6076 the fat content of the ground meat instream 6098 can be selected. The fat content of the ground beef in thestream pumped by pump 6070 is measured by the Epsilon (or other suitablefat measuring devices) fat measuring devices 6082. The fat content ofthe ground beef in the stream pumped by pump 6076 is measured by theEpsilon (or other suitable devices) fat measuring device 6086. Thevelocity of pumps 6070 and 6076 can therefore be controlled and set bythe fat measurements provided by 6082 and 6086. In this way, a selectedfat content can be produced by an automatic controller such as acomputer that is preferably connected to all associated pumps and fatmeasuring devices.

The fat and muscle (lean) content of the stream of ground meat that isshown as stream 6102 and which is delivered to grinder 6104, isdetermined by the fat and lean content of a quantity of ground meat fromboth stream 6042 via pump 6068 and an additional quantity of ground meatfrom stream 6044 via pump 6074. The fat and muscle (lean) content of thestream of ground meat that is shown as stream 6104 is also determined bythe velocity (and quantity of ground meat pumped there along) of theground meat stream pumped into junction box Y by pump 6068 and theground meat stream pumped into junction box Y by pump 6074. Preferably,adjusting the speed of pumps 6068 and 6074 the fat content of the groundmeat in stream 6102 can be selected. The fat content of the ground beefin the stream pumped by pump 6068 is measured by the Epsilon (or othersuitable fat measuring devices) fat measuring device 6080. The fatcontent of the ground beef in the stream pumped by pump 6074 is measuredby the Epsilon (or other suitable devices) fat measuring device 6080.The velocity of pumps 6068 and 6074 can therefore be controlled and setby the fat measurements provide by 6080 and 6074. In this way, aselected fat content can be produced by an automatic controller such asa computer that is connected to preferably all associated pumps and fatmeasuring devices.

The fat and muscle (lean) content of the stream of ground meat that isshown as stream 6106 and which is delivered to grinder 6108, isdetermined by the fat and lean content of a quantity of ground meat fromboth stream 6042 via pump 6066 and an additional quantity of ground meatfrom stream 6044 via pump 6072. The fat and muscle (lean) content of thestream of ground meat that is shown as stream 6106 is also determined bythe velocity (and quantity pumped there along) of the ground meat streampumped into junction box X by pump 6066 and the ground meat streampumped into junction box X by pump 6072. Preferably, by adjusting thespeed of pumps 6066 and 6072 the fat content of the ground meat instream 6106 can be selected. The fat content of the ground beef in thestream pumped by pump 6066 is measured by the Epsilon (or other suitablefat measuring devices) fat measuring device 6078. The fat content of theground beef in the stream pumped by pump 6072 is measured by the Epsilon(or other suitable devices) fat measuring device 6084 The velocity ofpumps 6066 and 6072 can therefore be controlled and set by the fatmeasurements provided by devices 6078 and 6084. Preferably, any quantityof ground meat with any selected fat content can be produced by anautomatic controller such as a computer that is connected to preferablyall associated pumps and fat measuring devices.

The configuration shown in FIG. 200 preferably provides for automaticproduction of three streams of ground meat 6110, 6112 and 6114, eachwith a selected fat and lean content. A configuration of the requiredequipment, with any chosen capacity and size to suit any rates ofproduction, can be arranged to produce any suitable number of one ormore streams of ground meat, each with a selected fat and lean content,as may be desired.

Overwrapping and Web Stretching Apparatus and Method

Controlled Atmosphere Packages (CAP) are packages prepared or treated inan oxygen deficient atmosphere to remove or prevent the accumulation ofoxygen within the package materials. Packages are overwrapped withapparatus having web stretching capabilities in one aspect of theinvention.

Referring to FIGS. 202-204, details of a controlled atmosphere packagingsystem according to the present invention is shown. FIG. 202 shows asection of PVC web material 6200 is about 0.0008″ in thickness.Preferably, any suitable thickness or gauge can be used. Preferably, web6200 can be coated, fully or in part and with any desired pattern suchthat parts of the web remain clear and other coated parts may be opaque.Web 6200 is shown with a suitable heat sealing coating that has beenapplied in two continuous strips along the edges of the web such that acontinuous, central strip remains clear. The width of the clear section6202 central strip may be about 50% of the total width of the web 6200and the outer two printed sections 6204 of about equal width being about25% of the full width each, of web 6200 such that when formed into atube 6214, a fin seal, 6308, can be provided by heat sealing theretogether. Preferably, a sealed tube including an upper clear sectionthrough which the tray 6210 can be seen and a lower, opaque section 6212through which tray 6210 cannot be seen.

Web 6200 can be processed by a modified Hayssen RT1800, for example, insuch a manner so as to form a continuous tube 6214, and shown as PVC webmaterial “fin” sealed tube. Suitable packaging trays such as Mono-Pak™trays 6210 that have been filled with perishable goods such as groundbeef can be inserted into the tube 6214, by automatic devices (notshown) or any other suitable devices, and lateral stretching can beinduced into the tube 6214. The lateral stretching can cause the tube6214 material to firmly contact the tray 6210 and hold the perishablegoods contained therein firmly. After the trays 6210 are located insidethe fin sealed tube 6214 the tube can also be stretched longitudinally.After the longitudinal stretching of the tube 6214, lateral fin seals,followed by severing of the tube 6214 adjacent to the lateral fin seals,can be provided so as to provide a fully and hermetically sealed packageas shown in FIG. 204. The lateral and longitudinal stretching can beprovided prior to sealing and severing of the lateral fin seals.Longitudinal stretching can be effected by the modified Hayssen RT1800after modification and as generally described below.

Referring now to FIG. 201, items 6000, 6002 and 6004 shown thereoninclude three modified versions of the Hayssen RT 1800 (modifiedRT1800), flow wrapping packaging machine. The modifications to each item6000, 6002 and 6004 refers to the inclusion of a sub-assembly to eachmachine which is detailed in a cross-sectional sketch shown as FIGS.205-206 so as to enable processing and use of pPVC web material on theRT1800 packaging machines. The following disclosure details themodification that can be incorporated in the RT1800 so as to facilitatethe use of pPVC web material as the over wrapping packaging materialused thereon to over wrap such packages as the Mono-Pak EPS foam tray.

The Hayssen RT 1800 is manufactured by Hayssen, a division of theBarry-Wehmiller Company, which is located at 225 Spartangreen Boulevard,Duncan, S.C. 29334. Other information describing the RT1800 can beobtained from the following web site: www.hayssen.com. The RT 1800incorporates a “rotary die wheel” in such a manner so as to provide acontinuous movement of the web during machine operation and packagesealing. This arrangement provides a method to process and seal packagesmore rapidly than other types of over wrapping machines but hitherto theRT 1800 has not been used to over wrap packages with pPVC (plasticizedpolyvinylchloride) web material.

It is desirable to use pPVC web material, in this particularapplication, because of its most suitable physical characteristics forthe packaging of fresh meats such as ground meats and poultry pieces.However, the standard RT1800 is not ideally suited to process pPVC webmaterial and in order to ensure efficient stretching and sealing of thepPVC web the modifications to the RT1800 are necessary.

The HAYSSEN RT1800 rotary die wheel concept operates on the principal ofmaximizing dwell time. Individual MAGNUM sealing dies are released ondemand as packaging material and product move through the machine. TheRT1800 packaging equipment is well known to those skilled in the artsand all details of the RT1800 machine construction are readily availablefrom the manufacturer to potential end users of this popular packagingequipment.

Packaging materials may include the Mono-Pak™ EPS tray, over wrappedwith plasticized PVC web material, (supplied by AEP/Borden or Huntsman).

It should be noted that the readily available, low cost, pPVC webmaterial as intended for use in this application, has the followingproperties:

1. Glass clarity

2. Stretch and high extensibility (50-100% before exceeding elasticlimit)

3. Memory, providing a “return to its original condition” afterstretching (within elastic limit).

4. Standard, enhanced oxygen permeability.

5. Rapid heat sealing to itself.

6. Rapid hot “knife” cutting, providing clean cut edges.

7. Generally, the basic RT1800 machine, as manufactured by Hayssen,would remain similar to existing standard equipment, except for themodification described herein. The existing longitudinal fin or lapsealing (as shown as 6208, in FIG. 203) may require adjustment tofacilitate an enhanced lateral web “stretching” capability for a pPVCweb. The longitudinal web stretching apparatus, as disclosed herein,should be capable of installation without major structural and basicframe modifications to the existing equipment.

FIGS. 205-206 include an assembly intended for optional andinterchangeable use on standard Hayssen RT1800 or similar packagingmachines, shows detail of the following items.

Referring now to FIGS. 205-206, the apparatus constructed according tothe present invention includes a die wheel 6216 shown in part with theaxis of the wheel marked as axis 6218. A number of die carriers 6220 arealso shown. The complete die wheel 6216 and drive is not shown, however,since a person skilled in the art will readily recognize the proposedmodification when viewing the representation of the die wheel with diecarriers as shown. The wheel die assembly fixture may include a standardHayssen component modified to suit convenient attachment of the “StretchWeb Clamp Assembly”.

The packaged product may include any of the number of trays disclosedherein, for example, the tray shown in FIG. 55, over wrapped withstandard (with enhanced O₂ permeability) plasticized PVC web material,(supplied by AEP/Borden or Huntsman). The EPS material can be producedwith a surface finish that will not “cling” to the pPVC web material.

Plasticized web of stretch over wrap material is preferably printed orplain material can be used. Preferably, partial coating of the insideweb surface, with a low melt heat activated coating (HAC), can providefor improved performance.

A full width, lateral, impulse, heat sealing, element (e.g. cut fromInconnell SS sheet or other “marine” grade, SS sheet material) isinstalled by attachment to a horizontally disposed rigid and suitablyheat tolerant, non metallic base. Preferably, compensation for normalexpansion and contraction of the element, during heating and cooling,can be provided. The element is covered with suitable material (PTFE) soas to provide a “non-stick” surface that will not “cling” to pPVC web.The heat sealing assembly is arranged with the heating sealing elementin close, adjacent and parallel disposition to a full length strip of aportion of the outer surface of roller 6224, as shown in the sketch.When held together under suitable pressure with two webs of pPVCmaterial located between member 6228 and roller 6224, a full length andhermetic seal between the two webs can be produced.

An alternative heat sealing device includes a heat bank. Use of eitherimpulse or heat bank devices may be determined by manufacturerpreference. In the case of a heat bank device, the clamping bars 6230and 6232 would be separated and insulated from the adjacent heat bankmembers 6230, 6232 and 6234, 6228 would require independent, returnspring mounting. A suitable distance or gap (for insulation andsealing/cutting control devices), between the elevation of the clampingsurface of the clamping bar and the elevation of the contact surface ofthe heat bank, would be required. This would allow clamping of theweb(s) by the clamping bar with subsequent web clamping, sealing andcutting by the heat bank.

Web clamping bar 6232 includes a strip like component that is arrangedin parallel and close proximity to assembly 6228 so as to provide aclamp to web 6236 at the same time and with similar clamping effect asmember 6232 when roller 6224, 6232 and member 6228 are arranged so todo.

Rubber coated roller with cam/clutch bearing 6224 includes a heatresistant rubber coated and suitably ground, solid steel, hardened,rigid roller. Roller 6224 is located between two end plates 6240 and6242 (not shown) and mounted thereto by bearing (one located at each endof the roller 6224. The bearings are of identical dimensions with“cam/clutch” feature provided in one only bearing. Such arrangementallows the roller 6224 to rotate in a clockwise direction only.

Impulse heat sealing element assembly is arranged to mirror imageassembly 6228.

Web clamping bar 6230 is arranged to mirror image web clamping bar 6232.

Rubber coated roller with cam/clutch bearing 6244 includes a heatresistant rubber coated, solid steel, hardened, rigid roller identicalto roller 6224 but with a “cam/clutch” feature provided in one onlybearing so as to allow roller 6244 to rotate in a counter clockwisedirection only, as shown by an arrow in the sketch. The surface finishon both rollers 6244 and 6224 can be arranged so as to cling to web 6236when contact occurs between suitably tensioned web 6236.

Two end plates 6240 and 6242 are arranged to rigidly retain rollers 6244and 6224 in relative, respective, parallel and separated proximity,allowing the rollers to rotate as described above. Both end plates maybe fitted with suitable coil or flat return springs to hold the rollers6244 and 6224 in a normal position at a desired distance from bars 6230and 6232 and heating elements 6234 and 6228.

A cam follower is mounted to each end plate 6240 and 6242 so as toengage with cam tracks (not shown but mounted to main frame of FFSmachine) arranged to provide a web sealing pressure to web 6236 bycausing depression of end plate return springs.

The web stretching bar 6226 includes a strip of suitable materialprofiled as shown and provided with an outer surface treatment that cancling to pPVC web material. Web stretching bar 6226 is attached to twopneumatic cylinders [6246 (shown) and 6248 (not shown)] with slottedfixture apertures so as to eliminate locking that may otherwise occurduring operation. The web-stretching bar is shown in a normallywithdrawn (closed) position and also in a fully extended position, bydotted lines. When in the normally closed position, the upper andhighest edge of the bar extends along its full length and is inpermanent contact with web(s) 6236. This contact is arranged so as toensure a suitable tension is induced in the web(s). This can provide acondition allowing the free movement (by stretching) of the web materialover roller's 6244 and 6224 only inwardly and toward the web-stretchingbar. The cam/clutches installed in the rollers will not allow the web tobe pulled away from the web-stretching bar. Preferably, web 6236 can befreely stretched but is essentially clamped by its tensioned andintimate contact with the surface of the rollers and the upper edge ofthe web-stretching bar.

The Rollers Assembly, includes two off each rollers, 6244 and 6224,endplates 6240 and 6242, cam followers 6250 and 6252, fasteners andreturn springs as required. When assembled with the complete webstretching assembly and in a normally closed position, a suitable gap ismaintained between the rollers and the adjacent contact surfaces ofitems 6230, 6234, 6232 and 6228, thereby allowing free stretching of theweb 6236, by activation of web-stretching bar 6226.

A pneumatic cylinder is shown, attached to the web-stretching bar 6226to extend bar 6226 to the position shown by dotted lines and therebystretch the web 6236. Preferably, two cylinders would be provided.Compressed air flow and pressure controls can be arranged to activatecylinders 6246 and 6248 so as to optimize induced tension in web 6236.Any suitable alternative method of web-stretching bar activation andcontrol may be used.

A vacuum tube may be conveniently located so as to provide a method ofremoving scrap web material (excess material for accumulation in acanister.

In this configuration independent pivoted mounting of each roller andclamping assembly 6256 and 6258 is provided. Each assembly 6256 and 6258is held in the normal central position (close together), by controlledreturn springs. Activation of the web-stretching bar 6226 will cause thetwo assemblies to move away from the central position until contact withthe packages 6254. Such an arrangement will provide consistent webstretching with a final web heat sealing at a constant distance from thepackage. In this configuration end plates 6240 and 6242 would requireslotting to accommodate outward rotation of each assembly.

Products, pre-filled with ground beef portions/blocks, are automaticallyloaded onto the entry end of the Hayssen FFS equipment. Orientation ofthe products may be in normal or inverted disposition. A normaldisposition (with package “open top” side facing upward) would require aside fin or lap web seal, whereas an inverted disposition would requirea bottom web seal. Normal operation would include longitudinal sealingafter induction of maximum stretch in web 6236. Lateral sealing wouldoccur after longitudinal stretching by web stretching bar 6226.Activation of the web-stretching bar would not commence until closure ofthe subsequent closing of the closest clamp to its rear, on the wheel.In this way gradual stretching of the pPVC over wrap, during the wheelrotation, can occur until the desired level of stretch and/or tension isachieved when web heat sealing and simultaneous cutting could beprovided immediately prior to ejection of the finished package(s). Thefinished packages could be ejected in a normal and upright disposition,assuming that the packages were loaded in an inverted disposition,alternatively, the packages could be inverted after ejection if thepackaging had been loaded onto the RT1800 packaging machine in anormally upright position.

By incorporating the above described modification in the Hayssen RT 1800packaging machine a web stretching arrangement is provided to stretchthe over wrap material 6236 during the normal rotation of the die wheel.It is anticipated that, in view of the rapid heat sealing and coolingcharacteristics of thin gauge (0.0008″) pPVC, the operational speed ofthe Hayssen RT 1800 could be increased to more than 1800 feet perminute.

Blending Apparatus

Referring now to FIGS. 207-208, details of an apparatus that can be usedto blend one or more individually controlled streams of ground meatsthat can also be combined with selected conditioning gases or suitablematerials and blended together to produced a single stream of blendedand conditioned ground meat, is shown. FIG. 208 shows a diagrammaticrepresentation of three streams of ground meats, 6300, 6302 and 6304that are each pumped through conduits shown as 6306, 6308 and 6310 atindependently controlled velocities. Preferably, the apparatus can bearranged to provide one or more streams of ground meat but mostpreferably three streams will be provided where, for purposes ofexample, one stream may have an approximate fat content of about 20%, asecond stream has an approximate fat content of about 30% and a thirdstream has a fat content of about 7%. Preferably, the content of eachstream can be varied as may be required. Conduits 6306, 6308 and 6310can be arranged to house independent measuring devices such as theEpsilon GMS-40 in-line measuring equipment. The streams of ground meatcan be pumped, by positive displacement pumps that are independentlydriven by variable speed drivers, at velocities that are continuouslyadjusted directly corresponding with the respective fat and musclecontent of each stream such that when the three streams are subsequentlycombined together into a single stream of ground meat, the fat andmuscle content of the combined stream is substantially consistent andconstant at a chosen composition with percentage quantities of fat andmuscle held within a range of less than about +/−1% fat content.Furthermore, even though the velocity of each separate stream of groundmeat is independently varied according to the fat and muscle content ofthe respective stream, the resultant single, combined stream can bearranged, by adjusting the velocity of each of the streams 6300, 6302and 6304, to be at a constant velocity, volume and production rate andas desired within the capacity of the apparatus.

Referring now to FIG. 207, a housing 1318 is arranged with six suitablyprofiled blades 6312 that are attached together at a central axis 6314which in turn are attached to a driver 6316. Blades 6312 are attached ataxis 6314 and to a driver 6316 in such a manner that blades 6312 can berotated within the confinement of housing 6318, which is sealed andseparate from external atmosphere. Blades 6312 are arranged so as to notcontact but be in close proximity to the internal surfaces of thehousing 6318. A total of six spaces or segments shown as 6320, aretherefore arranged between the blades 6312 that include equal volumesand a recess 6322 is provided at the axis of the blades 6312 so as toallow direct communication between the spaces. The direct communicationbetween the spaces 6320 may be provided or otherwise, if so desired, notprovided. A conduit 6324 is attached to the housing 6318 with a spiralauger 6326 contained therein. Auger 6326 may be directly connected tosuitable driving devices (not shown) that can provide a variable speedrotating of the auger as required to further blend the single stream ofcombined ground meats. Preferably, the streams of ground meat can betransferred directly through housing 6318 and into conduit 6324. Blades6312 can be rotated about the axis by driver 6328 at a suitable speed.Preferably, a series of conduits 6330 can be arranged to have directcommunication with the spaces between the blades 6312, as they rotateadjacent thereto, so as to allow injection of any suitable substancessuch as carbon dioxide into the spaces at any suitable pressure and froma suitable source and in controlled quantities. Preferably, a knownquantity of ground meats can be transferred from conduits 6310, 6308 and6306 into spaces 6320 with a known and controlled quantity of gas orother suitable substance provided therein via conduits 6330, as spaces6320 rotate about its axis 6322, and pass through conduits. Blades 6312are arranged with edges that are parallel and in close proximity to theinternal surfaces of housing 6318. As ground meat is transferred fromthe conduits into the spaces 6320 at controlled rates and quantities,controlled quantities of carbon dioxide can also be transferred into thespaces. Preferably, selected quantities of ground meat and carbondioxide can be transferred, consecutively, into spaces 6320 andtransferred as a single volume of materials into conduit 6324 andblended therein, in a continuous process of measured amounts of groundmeat and carbon dioxide. Preferably relatively small quantities ofmeasured amounts of ground meat with a selected quantity of carbondioxide can be blended most efficiently in a continuous process. Such amethod of blending can provide a method of thorough and accurateblending with a minimum energy requirement. It can now be seen that theapparatus herein described can be used to efficiently produce a blend ofground meats that has been pre-conditioned with such substances ascarbon dioxide and at a chosen rate of production within the capacity ofthe apparatus. The apparatus shown in FIGS. 207-208 can be enclosed inany suitable jacket or containment so as to allow any suitable heatexchanging medium to contact the housing and thereby, by a heatexchanger means provide precise temperature control of the apparatus andany goods processed therethrough. The temperature control can be preciseand set at any suitable temperature within any suitable temperaturerange. In a preferred embodiment the conduit 6324 may include a suitableportion of static mixing conduit as may be supplied by Statiflo,alternatively auger 6326 may be driven by a suitable driver at anysuitable speed. Conduit 6324 may be connected to a suitable positivedisplacement pump or other suitable pump so that any goods that may havebeen processed by the apparatus shown in FIGS. 207-208, can be directlytransferred thereto and then pumped at a desired rate into suitableholding containers or directly into further processing and/or packagingequipment.

Pre-Conditioning Apparatus

Referring now to FIG. 209 a side elevation of a ground meatpre-conditioning apparatus intended for use in pre-conditioning groundmeats and any other suitable goods, is shown.

Preferably, the pre-conditioning apparatus is intended for use topre-condition such perishable goods as ground meats in a continuousprocess (as opposed to a batch process where the perishable goods may betransferred into a pressure vessel which is then sealed prior to removalof any undesirable gases and provision of desirable and suitable gasestherein). The continuous process may be arranged so that the groundmeats are continuously transferred through an entry orifice thatrestricts the transfer into a vessel in such a manner so as to provide aseal. The vessel can be filled with any suitable gas at any suitablepressure and maintained at any suitable temperature. The vessel can bearranged to accommodate any suitable quantity of the ground meats forany suitable period of time or residence time. The ground meats can bearranged to exit the vessel after a suitable period of time by transferthrough a restricting exit orifice. The exit orifice and the entryorifice can be arranged to restrict transfer of ground meatstherethrough in such a manner so as to prevent suitable gases providedin the vessel from escaping therefrom.

A meat hopper 5400, meat grinder 5402 and drive motor 5404 is arrangedto grind meat which passes from the meat grinder 5402 directly into afirst conical shaped connection to a tube 5410. Tube 5410 includes alength of high pressure stainless steel tube or other suitable material,and connects with a second conical shaped connection 5412 to grinder5408. First conical connection 5406 is provided so as to elevate thepressure of the ground meat as it is transferred from said grinder 5402to tube 5410. Tube 5410 may follow any convenient path and is arrangedto have any suitable length and, save two end portions of convenientlength, is located in an insulated tank enclosure 5414 that contains asuitable liquid cooling medium 5416, such as brine or glycol. Tube 5410can be completely immersed in the cooling medium 5416 which can bemaintained at a desired and suitable temperature that may be set betweenabout 32 and about 33 degrees F. Another tube 5418 connects the tankenclosure 5414 to a heat exchanger 5420 via a suitably sized pump 5422.Tube 5424 connects the tank enclosure 5414 to the heat exchanger 5420.The pump 5422 is arranged in such a manner that cooling medium 5416 canbe pumped at a controlled rate through the heat exchanger 5420 so as tomaintain 5416 at a desired temperature. Tube 5426 connects the heatexchanger with a source of suitable gas 5428, such as carbon dioxide,provided at a suitable volume, temperature and pressure. Tube 5430 isarranged to carry any excess quantities of gas 5428 away from heatexchanger 5420 as may be required. Tube 5426 is arranged to connect gas5428 supply to tube 5410 via the heat exchanger 5420 and connects to thetube 5410 at connection 5432. Connection 5432 is arranged to allow aconstant flow of gas 5428 directly into or through suitable valvesattached to tube 5410 at a position approximately equal distance fromeach end of tube 5410.

Meat, which may have been dipped in or sprayed with any suitablebactericide such as natural citric acids, is loaded into the meat hopper5400 at a convenient rate and is processed by grinding in the meatgrinder 5402. Meat grinder 5402 is driven by drive motor 5404 at asuitable speed and ground meat which may be coarse ground, is forcedinto the first conical connector at a suitable pressure. Ground meat istherefore forced under suitable pressure into and along tube 5410. Dueto the immersion in the medium 5416, the temperature of the tube 5410 isapproximately equal to the temperature of the medium 5416 and thereforetemperature of the coarse ground meat is affected and will be eitherheated or cooled accordingly. The coarse ground meat can be held in thetube 5410 for such a period of time that will allow the temperature ofthe coarse ground meat to become substantially equal to the temperatureof the medium 5416 by transfer of heat through the walls of the tube5410. The coarse ground meat can pass through the entire length of thetube 5410 and into the second conical shaped connection 5412 to grinder5408. Grinder 5408 is driven by motor 5434 and is arranged to grind thecoarse ground meats and can be further arranged to produce fine groundmeat from coarse ground meat. A speed controller can be arranged tocontrol the speed of motor 5434 and the corresponding production rate oroutput of the grinder 5408 can thereby be controlled as may be requiredto correspond with the speed and output of the grinder 5402. Suitablegas 5428 can be injected at a suitable rate, into tube 5410 via tube5426, at a suitable temperature which may be equal to the temperature ofmedium 5416, and at a suitable pressure which may be about 200 psi. Gas5428 may be carbon dioxide and can therefore dissolve into coarse groundmeat as it passes through tube 5410. The diameter of tube 5410 can bearranged to be smaller than the internal diameter of grinders 5402 and5408. The source of gas 5428 can be arranged to provide gas at asuitable pressure and in quantities sufficient to meet the desired rateof absorption by the ground meat passing through the tube 5410 and alsothe quantity required to maintain medium 5416 at the desiredtemperature. If the volume of gas 5428, required to maintain thesuitable temperature of medium 5416 exceeds the volume of gas requiredto be provided into tube 5410 then excess gas can be vented toatmosphere through tube 5430. Conversely, if the quantity of gas 5428required to be provided into tube 5410 is greater than the quantityrequired to maintain the temperature of medium 5416 at a suitable level,such that the temperature of medium 5416 is otherwise thereby depressed,then a heater can be provided. The heater can be arranged to heat gas5428 as required to ensure and maintain the temperature of medium 5416as required.

A suitable device to vary the quantity of medium 5416, that is pumped bypump 5422 through tube 5418 can be provided. Gas 5428 may be injectedinto the tube at any suitable gas pressure that may be 200 psi, however,under such conditions gas 5428 will be soluble and therefore dissolve inliquids contained in tube 5410, resulting in a pressure drop as the gasand liquids are transferred along tube 5410 toward grinder 5408.

The quantities of gas 5428 and ground meat present in tube 5410 and thelength of tube 5410 can be arranged so as to allow partial or completedissolving of gas 5428 into ground meat while still present within tube5410.

It may be important that ground meats are not exposed to conditions thatwill either partially or fully freeze the ground meats during processingin the pre-conditioning apparatus. Accordingly, heat exchanger 5420 canbe arranged so as to provide a method of transferring heat between theground meat within the tube 5410 and gas 5428, and medium 5416 asrequired and in such a manner that will inhibit and/or prevent freezingof the ground meat during the pre-conditioning process. Heat exchanger5420 can be arranged so as to provide a method to ensure that,irrespective of the temperature of the meat provided in the hopper 5400,the temperature of the ground meat 5436 will be maintained at a suitabletemperature that may vary within a limited range of plus or minus about0.5 degrees F. Ground meat 5436 can be processed in the pre-conditioningapparatus so as to saturate or partially saturate, to any suitablelevel, the ground meat with any suitable dissolved gases.

Preferably, any suitable gas such as nitrogen may be provided directlyinto grinder 5402 through tube 5438 shown, so as to substantially purgeand remove any air that may be present with the meat in hopper 5400. Thequantity of meat transferred along tube 5410 and the quantity of gas5428 injected into the tube 5410 at connection 5432 can be measured andcontrolled with motors 5404 and 5434 and pump 5422, by a programmablelogic controller (PLC). Ground meat pre-conditioning apparatus may becontrolled by any suitable controller so as to provide an automaticprocess. The apparatus can be manufactured to suit any required rate ofproduction.

An auger or other pump to assist in transfer of the ground meat throughtube 5410 may be located between the meat grinder 5402 and the firstconical connection 5406 or any other suitable location.

A suitable tube (not shown) and valves to open and close the tube, maybe provided to connect the second conical connection 5406 to the meatgrinder 5402 thereby allowing any re-cycling of ground meats that haspassed through tube 5410. Such a re-cycling would allow for furtherpre-conditioning of any goods that had not been correctly processedduring a first passage through tube 5410.

Vents to allow excess gas may be provided at suitable locations in tube5410 or at any other suitable location.

Ground meat 5436 may be further processed by direct transfer fromgrinder 5408 to any other suitable processor such as a pattie formingmachine or directly into a vacuum packaging machine. The transfer of theground meat 5436 may be via an enclosed mode of transfer so as toeliminate or minimize exposure to ambient atmosphere prior to furtherprocessing or packaging.

The pre-treatment of any perishable goods, such as ground beef, asdescribed herein can enhance the keeping qualities of the perishablegoods. Preferably, the goods can be placed into a sealed pressure vesselwith a known quantity of suitable gases at any suitable pressure for asuitable period of time and maintained at a suitable temperature.Preferably, the suitable gas pressure may be selected at a pressureabove ambient air pressure. The quantity of the suitable gas can beincreased by providing additional controlled quantities into thepressure vessel as desired. Preferably, the suitable pressure, time andpre-treatment temperature can be precisely controlled and arranged so asto allow the suitable gas to dissolve into any water and oils and/orother substances contained in the goods. The quantity of suitable gasthat dissolves into the goods, can therefore be controlled and may beequal to the maximum amount that can dissolve therein at any suitablegas pressure and thereby saturating the goods with the suitable gas insolution. Preferably, a known amount of gas can be dissolved into thegoods at a given gas pressure and pre-treatment temperature. Theperishable goods can then be removed from the pressure vessel andpackaged in any suitable packaging such as a hermetically sealed vacuumpackage that may include a gas barrier plastic pouch of suitable size.Preferably, after vacuum packaging the perishable goods into thesuitable gas barrier pouch at ambient air pressure, the goods can bestored in ambient atmosphere and maintained within a suitable storagetemperature range. The suitable storage temperature range can bemaintained at a suitable level above the pre-treatment temperature.Preferably a quantity of dissolved gas can emerge from the perishablegoods and partially inflate the gas barrier pouch. The size of the gasbarrier pouch can be arranged to accommodate the partial inflationwithout damage to the hermetic sealing of the pouch. The emerged gasthen contained within the gas barrier pouch can enhance the keepingqualities of the perishable goods. The emerged gas can subsequentlydissolve into the goods again and re-emerge corresponding to anytemperature fluctuations that may occur within the suitable storagetemperature range. Preferably, a quantity of free suitable gas can bemaintained in gaseous condition with the goods within the packaging andthe quantity of free gas can be arranged and controlled at a minimumsuitable quantity. However, if the temperature of the goods in the gasbarrier pouch is increased as a result of failure of refrigeration orany other type of temperature “abuse” to an unacceptable high level (forexample 50 degrees F.) for an unacceptably prolonged period so that thequality of the goods is compromised, additional gas will be releasedfrom solution therein and cause further expansion of the gas barrierpouch. The gas barrier pouch can be sized such that it will accommodatea known amount of released gas. The known amount of the released gas canbe limited to such an amount that will be released by goods at anacceptable temperature and if the acceptable temperature is exceeded anyadditional release of gas can cause rupturing of the gas barrier pouch(or any other suitable packaging material). Rupturing of the packaging,therefore, can be used as an indication that goods have endured anunacceptable level of abuse.

In yet another preferred embodiment, goods may be treated by exposure toan adequate quantity of suitable gases at a suitable temperature andpressure in such a manner so as to allow a specific quantity of suitablegas to dissolve in the goods. The specific quantity of suitable gas canbe arranged so as to equal an amount that will saturate the goods withthe suitable gas dissolved therein to a suitable level. The goods canthen be packaged in any suitable packaging of suitable size which mayinclude an additional quantity of suitable gas contained andhermetically sealed in the suitable packaging with the goods therein.Preferably the total volume of the goods with specific quantity ofsuitable gas dissolved therein plus additional quantity of suitable gascan be arranged so as to completely fill the suitable packaging ofsuitable size to provide a finished package with goods and the gassealed therein. Therefore, any change in temperature of the finishedpackage and the goods therein will result in a change in the totalvolume of the goods plus the additional quantity of suitable gas. Thepackaging, the goods with the suitable gas dissolved therein plus theadditional quantity of suitable gas can be arranged so as to accommodatea known variation (increase or decrease) in the total volume, asdesired. The known variation can be used as an indicator of thetemperature history of the finished package. For example, the packagingmay be provided with a valve indicator that will permanently open orbreak if the temperature of the finished package with the goods,increases to an unacceptable level and extent so that the volume of gastherein and corresponding pressure thereof increases to an unacceptablelevel.

Primal Meat Portion Shaping Apparatus

Referring now to FIG. 210, an apparatus for shaping primal meat portionsincludes a container 2800 and plug 2802. Container 2800 and plug 2802may be manufactured by injection molding a plastics material such asnylon or alternatively a gas permeable and porous material such as achemically foamed polypropylene or polyester plastic material.Alternatively the container and plug may be manufactured from astainless steel mesh. The apparatus includes a container 2800, with lugs2842 and 2844 that are engaged with rails 2814 and 2846. The rails mayinclude, for example, parallel, round, stainless steel bars, suitablymounted to framework, conveniently spaced apart and horizontallydisposed, extending for any convenient and desired length that may havebends and curves allowing for the powered or manual movement of thecontainers 2800 there along while maintaining engagement between thelugs and horizontal rails. The cross-section shown in FIG. 210 providesdetail of the container, plug and apparatus through one cross-sectiononly. Other views are not considered necessary since the profile of thecontainer and plugs, across a different section may be similar,differences may only include variations in for example, length. Themechanism, container and plug may be arranged in any suitable anddesired shape and size to suit the requirements for each portion ofpre-rigor fresh red meat. Generally, the internal volume of an assembledcontainer with a corresponding and matching plug in position, isapproximately equal to the volume or displacement of the correspondingfresh red meat primal shown as 2822. The plug 2802 can slide inside theopening of the corresponding container 2800 such that rim 2810 remainsin contact with the inside surfaces of the container wall. Thedisplacement of similar fresh red meat primal that have been harvestedfrom different animals will vary. Therefore, in order to accommodate thevariation of similar fresh red meat primals, the internal volume, shownas space 2812, of the assembled container and plug can be adjusted tosuit the actual displacement of the corresponding fresh red meat primal.The fresh red meat primal 2822 is located in the container and a plug2802 is located inside the upper portion of the container such thatsubstantially all air has been excluded from the enclosed cavitycontaining the primal, under the plug. The container 2800 is shownlocated in close proximity with a press base 2848, with perimeter wall2850. The press base is mounted onto an elevating shaft 2852 therebyproviding a means to elevate the press base so as to contact and retainthe lower portion of the container 2800, and also lower the press baseparallel with shown center line, such that the 2800 will be suspended onthe rails 2814 and 2846 and the press base will not contact or interferewith 2800 and allow the container to slide freely along the length ofthe rails when the press base is in a lowered position. An assembly,including an outer wall 2816 with a series of driven, concentricallymounted clamps, about a central clamp and located therein, is positioneddirectly above and aligned with the press base 2848. The wall 2816, andclamps marked 2818, 2828, 2826, 2824 are independently driven in areciprocating and vertical direction, parallel with the center lineshown. A concentric slot 2860 is provided around the perimeter of theclamp 2816, such that a vacuum can be applied to the upper side of thecontainer. A side view of an alternative profiled plug 2856 is shown inFIG. 211.

The container includes a rectangular, round or oval plan profile with aflat bottom and substantially vertical walls extending upwardly from thebase. The base and walls are continuously attached via a suitablyradiused confluence. Two lugs are conveniently located, one on eachopposing side of the container. The consistency of container 2800 issuch that it will deform slightly when subjected to pressure but willreturn to its original shape when the pressure is released. A bevel 2806is molded as shown to provide an easy penetration by the plug 2802.

Plug 2802 includes a “rigidly” flexible, relatively shallow cup with aflat or profiled face 2808, and flexible walls with tapering thicknessand flaring outwardly at an angle of about 5 degrees from vertical. Theupwardly extending walls are connected to the plug face with a radiustherebetween as shown. The upper rim, 2810, of plug wall is tapered andflexible.

The profile and dimensions of the plug are arranged so as to provide aneasy penetration into the matching opening of the correspondingcontainer. However as the plug penetrates the container opening, thetapered disposition of the walls provides for intimate contact andsealing between rim 2810 and inner surface of container vertical walls.The container and plug, when assembled together, provide an enclosedspace 2812 that is substantially sealed and isolated from externalatmosphere. Space 2812 has a volume that can be varied within thelimitations of the container, by moving the plug position, relative tothe container, within the container. In all positions, however, theintimate contact between rim 2810 and the inside surface of thecontainer walls is maintained in a substantially “airtight” fashion.

Preferably, containers and matching plugs of different sizes andsuitable profiles may be manufactured to suit various sizes of primalportions of fresh red meat, however, in each case the container andcorresponding plug are sized to provide a limited but variable internalvolume of space shown as 2812. Preferably, primal meat portions, oflimited varying size and profile can be accommodated within the samecontainers provided for similar primal portions.

It should be noted that animals used as a source of primal meat portionsvary in profile and size but are typically graded prior to slaughtersuch that the corresponding primal portions are approximately similar.

This present invention provides for de-boning of carcasses that arestill in pre-rigor mortis condition, immediately after animal slaughterand preparation while the temperature of the carcass remains close tonormal body temperature. The de-boning of the carcasses at suchtemperatures is very much easier and provides for much more rapidcompletion of the de-boning process, thereby substantially reducingcosts. Furthermore, pre-rigor mortis disassembly provides theopportunity to control and “mold” the primal meat portion profile suchthat when the primal portions are chilled, the firm, rigor mortiscondition occurs after shaping within the container and plug.

More specifically, according to this present invention, the pre-rigormortis primal meat portion, having been de-boned, is sprayed with ordipped into a solution of one or more of the following: carbonic acid,acetic acid, ascorbic acid, citric acid and any other suitable substancethat can be used to inhibit or eliminate bacterial growth on the primalmeat portion. Primal meat portion is then placed into a container ofcorrespondingly suitable dimensions and a plug is inserted into the openend of the container. The assembled container, primal meat portion andplug is located with plugs engaged onto rails 2814 and positioneddirectly and in alignment above the press base. The press base iselevated so as to closely retain the container. The wall 2816 is loweredso as to engage with the outer surface of the upper portion of thecontainer walls as shown in FIG. 210. Clamp 2818 is then lowered andpenetrates opening of the container with radius 2820 end with bevel 2806and stretching the container opening outwardly thereby clamping itagainst the inner surface of wall 2816 and providing an airtight sealtherebetween. Wall 2816 is attached to an upper plate (not shown)forming a chamber that is isolated from external air. A vacuum source isattached and air is evacuated from between clamping assembly and plug.Progressively, Clamp 2818 is lowered so as to compress the plug againstprimal, followed by clamp 2826 and finally clamp 2828 is lowered. Clamps2828, 2826, 2824 are then in contact with the upper surface of the plugand all applying suitable pressure. The vacuum source is thendisconnected, allowing atmospheric air to apply pressure to the outersurface of the plug. In this manner, substantially all air can beremoved from within the container assembly.

The container assembly can then be immersed into brine or other suitablytreated, bacteria free, temperature controlled medium that may beelevated to as much as about 140 degrees F. and held for a suitableperiod so as to cause death of bacteria that may be present. Followingthe desired reduction or elevation of the primal temperature, thecontainer assembly can be relocated within a pressure chamber andexposed to an ultra high pressure on the order of about 30,000 psi ormore. This procedure can tenderize the primal and also kill bacteriathat may be present.

Alternatively, sequentially or simultaneously, the container assemblycan be attached to an electrical source so as to provide passing a highvoltage current through the primal and thereby treat by way of “Ohmic”heating. In this manner, any bacteria that may be present with theprimal can be substantially eliminated or killed.

The assembled container can then be removed from the pressure chamberand again immersed in a cooling medium when the temperature of theprimal can be reduced to a desired and optimum temperature prior toremoval from the container and followed by automatic slicing. In thismanner rigor mortis occurs such that the shape of the primal meatportion after cooling within the container is similar to the innerprofile of the container, providing a more efficient shape for slicingwith automatic slicing equipment.

Referring now to FIG. 212, an adjustable container arranged to provide adesired internal profile that can be used to contain, and thereby mold,a suitable cut of meat that has been separated by cutting from an animalcarcass immediately after slaughter of the animal and prior to rigormortis of the animal carcass. FIG. 212 shows details of a moldingassembly apparatus constructed according to the present inventionincluding an adjustable container 2830, constructed from any suitablemetallic or plastics material, that provides a desired internal spacewith a suitable profile, is shown. Apparatus can be used to contain inthe internal space, and thereby shape by molding to the profile therein,any suitably cut meat primal, that has been separated by cutting devicesfrom an animal carcass immediately after slaughter of the animal andprior to rigor mortis of the animal carcass and primal cuts. Theapparatus may be arranged in any suitable manner including thearrangement shown in FIG. 212 which is constructed from four components,including a “trough” shaped member 2832, a mating closure 2834 and twoidentical plugs 2836. Plugs 2830 are profiled to act as “pistons” in aconduit that is arranged by assembly of the components 2832 and 2834.The conduit includes member 2832 with mating member 2834 which, when ina closed and operating position, has an irregular cross-section profileand the “piston” like plugs, 2836 are arranged to sealingly fit, closelywithin the conduit. The conduit has parallel horizontally disposed wallsthat provide the conduit along which the “piston” like plugs can bepositioned at any desired location within the conduit and therebyproviding a space, between plugs 2836, into which item 2838 can belocated. The apparatus is arranged to be stackable and the lower, outersurface of member 2832 is profiled to mate with the upper externalsurface of member 2834 by “nesting” therewith when stacked in avertically arranged column.

A suitable (pre-rigor mortis) primal cut of meat, 2838 such as a NewYork Strip primal, can be placed in trough 2832, with plugs 2836positioned, one at each end of primal, to provide a defined space withprimal located therein. Member 2832 can be mated with member 2832 andclosed so as to contact plugs 2836. Members 2832 and 2834 can be fixedin position relative to each other and plugs 2836 can be moved, bymechanical powered devices and under pressure toward each other so as tocompress item 2838 to the extent required that will cause item 2838 toadopt a profile identical to the internal profile of the space definedby members 2832 and 2834 and plugs 2836. Assembly including members2832, 2834 and plugs 2836 with item 2838 contained therein can be fixedby any suitable method to a finished configuration and stacked withother similar assemblies such as on any suitable pallet. Pallet withassemblies stacked thereon, can then be re-located into a temperaturecontrolled chamber. Temperature controlled chamber can be set at anysuitable temperature that may be elevated up to not more than about 140degrees F. for a selected period of time after which the temperature maybe gradually reduced to about 29.5 degrees F. Item 2838 will thereforecool and rigor mortis will cause “setting” of the profile of item 2838.Item 2838 can then be removed from molding assembly and sliced. Slicingcan be conducted automatically while located inside an oxygen freechamber and with carbon dioxide or any other suitable gas or blend ofgases provided at any suitable pressure, present therein.

In another preferred embodiment smaller portions of pre-rigor bonelessmeat such as beef can be placed into the container assembly andprocessed therein in such a manner that will result in smaller pieces ofpre-rigor boneless meat adhering together to form a single piece thatcan then be sliced into consumer desirable slices. Pre-rigor bonelessbeef may include portions of fat and muscle tissue that can be placedinto the container, prior to processing, in any desired arrangement suchthat after processing, the single piece of meat will have a similarappearance to a primal such as a New York strip. In this way, lessvaluable smaller pieces of boneless beef can be used to produced largerand more valuable primal cuts of beef.

Containers and Plugs for Shaping Meat Primals

FIG. 215 shows a container and plug 3802, which may be manufactured byinjection molding and from a plastics material such as nylon oralternatively a gas permeable and porous material such as a chemicallyfoamed polypropylene or polyester plastics materials may be manufacturedfrom a stainless steel mesh. Preferably, a plurality of profiles of thecontainers and plugs that facilitate an adjustable volume feature willbe required in order to provide for all primal shapes and sizes. Forexample about 80 different containers and plugs would be required toaccommodate all of the various shapes of primal meat portions that aretypically produced in the dis-assembly of a single beef cow.

The container may typically include a rectangular, round or oval planprofile with a flat bottom and substantially vertical walls extendingupwardly from the base. The base and walls are continuously attached ata suitably radiused confluence. One, two or more lugs 3804 can beconveniently located, one or more on each opposing side of the containerto locate the container onto rails 3800 so as to retain and hold thecontainer in a desired position at a desired height from the floor. Therails may be arranged with an electrically or pneumatically powereddriver to move or slide the container along the rails, to anotherposition for further processing such as placing the plug 3802 inposition by automatic or mechanical apparatus, after loading the primalinto space 3808. The consistency of the material from which thecontainer is manufactured can be such that it will deform slightly whensubjected to pressure but will return to its original shape when thepressure is released. A bevel 3810 is provided as shown so as tofacilitate an easy penetration by the plug 3802 or 3812, into theopening in the container.

The plug may be provided in various profiles. An alternative plug 3812is shown in FIG. 216 with additional details shown in enlargedcross-sectional view of FIGS. 218-219. The plug includes a “rigidly”flexible, relatively shallow (shallower than the container 3800), “cup”shaped plug, with a flat or suitably profiled face 3814, and upwardlyextending, flexible walls 3816 with tapering thickness, flaringoutwardly and terminating at a rim 3818. The flexible walls can beprovided at an angle of about 5 degrees from vertical relative tohorizontal face 3814. The upwardly extending walls are joined to theplug face 3814 with a suitable radius therebetween as shown. The upperrim 3818 of the plug wall is tapered to provide a thin cross-section atthe outer edge of the lip and is flexible. An additional rim 3820located on the opposite side of recess 3822 as shown, that follows apath around the perimeter of face 3814 thereby providing a recess. Slots3824 are provided through rim to a depth equal to the height of the rimsuch that the base of each slot is on the same plane and level withface. Slots allow liquids such as liquid purge and blood to escapetherethrough and then between the flexible walls of the plug and theinner surface of the container 3800. A controlled and pre-determinedpressure P can be applied to the plug 4101 as shown in FIG. 221 so as tocause the liquid purge to be expelled from space 4107 through sides4105. The pressure P is equal to the weight W of red meat primalcontained therein multiplied by a constant x. Constant x is determinedby the type of meat being processed and could be equal to W, or severaltimes W and is determined by customer quality requirements.

The profile and dimensions of the plug are arranged so as to provide aneasy penetration into the matching opening of the correspondingcontainer, however, as the plug penetrates the container opening, thetapered disposition of the walls provides for intimate contact andsealing between the rim 3818 and the inner surface of the containervertical walls. The container and plug, when assembled together as shownin FIG. 216 provide an enclosed space 3808 that is substantially sealedand isolated from external atmosphere. The space 3808 has a volume thatcan be varied within the limitations of the container, by moving theplug position, relative to the container. Preferably, however, theintimate contact between the rim 3818 and the inside surface of thecontainer walls is maintained in a substantially “airtight” fashion.

More specifically, according to this present invention, the pre-rigormortis primal meat portion, having been de-boned, is sprayed, washed ordipped in a solution including one or more of the following: carbonicacid, acetic acid, ascorbic acid, citric acid and any other suitablesubstance that can be used to inhibit or eliminate bacterial growth onthe primal meat portion. The primal meat portion is then placed into thecontainer of correspondingly suitable dimensions and the plug isinserted into the open end of the container. The assembled container,primal meat portion and plug can be located with the lugs engaged ontothe rails and positioned directly and in alignment above the press base.The press base is elevated so as to closely retain the container asshown. The wall 3830 is lowered so as to engage with the outer surfaceof the upper portion of the container walls as shown in FIG. 216. Clamp3832 is then lowered and penetrates opening of the container with radius3834 engaging with bevel 3810 and stretching the container openingoutwardly thereby clamping it against the inner surface of wall 3830 andproviding an airtight seal therebetween. Wall 3830 can be attached to anupper plate (not shown) forming a chamber that is isolated from externalair. A vacuum source is attached and air is evacuated from betweenclamping assembly and plug. Progressively, 3836 is lowered so as tocompress the plug against primal 3838, followed by clamp 3840 andfinally clamp 3842 is lowered. Clamps 3842, 3840, 3836 are then incontact with the upper surface of the plug and all applying suitablepressure. The vacuum source is then disconnected, allowing atmosphericair to apply pressure to the outer surface of the plug. In this manner,substantially all air can be removed from within the container assembly.

The container assembly is opened as follows: A port 3844 is shown in thecontainer base. The port is provided to allow connection to a source ofcompressed clean gas or clean air. The compressed gas can then beinjected through the port and assist in the removal of the primal whendesired or after the primal has been stored in the container for adesired period of time.

The assembled container and plug with the primal contained therein maybe immersed into clean water, brine or other suitably treated, bacteriafree, temperature controlled medium that is temperature controlled byrefrigeration. Following the desired reduction or elevation of theprimal temperature the container assembly can be relocated within anultra high pressure (UHP) chamber and exposed to an ultra high pressureon the order of about 30,000 psi to about 100,000 psi or more. Thisprocedure can tenderize the primal and also kill bacteria that may bepresent. UHP equipment used may be similar to such equipmentmanufactured by Flow International, Incorporated of Kent, Wash., USA.

Alternatively, sequentially or simultaneously, the container assemblycan be attached to an electrical source so as to pass a high voltagecurrent through the primal and thereby treat by way of “Ohmic” heating.Preferably, any bacteria that may be present with the primal can besubstantially eliminated or killed.

The container and plug assembly can then be removed from the pressurechamber and again immersed in a cooling medium when the temperature ofthe primal can be reduced to a desired and optimum temperature prior toremoval from the container and followed by automatic slicing. In thismanner rigor mortis occurs so that the shape of the primal meat portionafter cooling within the container is similar to the inner profile ofthe container, providing a more efficient shape for slicing withautomatic slicing equipment.

In another preferred embodiment the container may be arranged and usedto process several, smaller, (thinner) fresh primals simultaneously.This can be achieved with the use of partitions or separating plates.The separating plates can be interposed between the smaller fresh primalportions in an arrangement that can include placing a first primal intothe container followed by a separating plate, followed by a secondprimal, followed by a second separating plate, followed by a thirdprimal, followed by a plug. Any quantity of fresh primal portions, thatcan fit within the container, can be processed in this manner.

Containers and Plugs for Shaping Multiple Meat Primals

In another preferred embodiment, the container may be arranged and usedto process several primals simultaneously. FIG. 217 shows an assemblyconstructed according to the present invention that includes container3900, a first 3902, second 3904 and third 3906 primal with first 3908and second 3910 separating plates therebetween. The plug is shown inposition after insertion and all air has been removed from the spacebetween the container base and the plug 3812. The assembly can then beimmersed in cooling medium for further processing and chilling.

In yet another preferred container embodiment, the container may bearranged and used to process several primals simultaneously without theuse of separating plates. FIG. 220 shows detail of a cross-sectionthrough an assembly constructed according to the present invention thatincludes a container 4000 with a first 4002 and second 4004 tenderloincontained therein. The plug 4006 is shown in position after insertionand substantially all air has been removed from the space between thecontainer base and the plug. The assembly can then be immersed in acooling medium for further processing and chilling. This process canprovide an apparatus of attaching two tenderloins together to produce asingle tenderloin of uniform profile and cross-sectional shape. Thetenderloin can then be removed and sliced into slices of equal profilesize and weight.

In yet a further preferred embodiment, the primal meat portions can beremoved from the container 4100, after chilling and rigor mortis, andsliced automatically and without separation of slices. Preferably, afterslicing and while still generally held together in a single item, thesliced primal meat portion can be placed into a preformed gas barrierbag and sealed therein or alternatively placed into a gas barrierpackaging tray that has been automatically thermoformed, in-line on amachine such as a Multivac R530 (Manufactured by Multivac SeppHaggenmuller GmbH & Co. The gas barrier packaging tray can be profiledand shaped so as to be similar and/or identical in internal profile tothe container 4100. The gas barrier packaging tray can then be locatedinto a vacuum chamber and a substantially gas barrier lid, that may be askin vacuum package (otherwise known by those skilled in the arts, asSVP), and conveniently heat sealed therein at flanges around the cavityof the gas barrier packaging tray. Preferably, a hermetically sealedprimal meat portion package can be produced that contains the primalmeat portion that has been conveniently sliced according to a customerspecification and requirement. The vacuum or SVP packaging process, thatcan be automatically performed with the use of R530 can rapidly andautomatically produce a plurality of the hermetically sealed primal meatportion packages can be stored in temperature controlled storageconditions. Preferably, a hermetically sealed primal meat portionpackage can be further processed by UHP apparatus prior to sale anddelivery to customers.

Plant Layout

Referring now to FIG. 222, a preferred equipment layout according to thepresent invention includes three rectangular components being identifiedby the reference numeral 3350. Preferably, the equipment includes threesimilar components. Each component is arranged to form a horizontallydisplaced, rectangular or square tube with doors at each end. The tubeis conveniently position so that access to the doors at each end of thetube can be accessed for loading of packaging materials into the tube.When the doors are shut, the tube is sealed to provide a fully enclosedcontainer or enclosure in which the EPS or FP trays can be stored.Conveniently located ports are provided into the walls of the tube suchthat suitable gasses can be introduced as required within the tubethereby displacing substantially all atmospheric air and mostparticularly atmospheric oxygen there from.

The tube is loaded with quantities of EPS and/or FP trays and the doorsare closed to provide a sealed container. Most preferably nitrogen,other inert and/or any other suitable gasses are provided into the tubeso as to displace substantially all air from the interior of the tubeand thereby providing a condition where the gas is in contact with thesurface of the EPS and/or FP trays. Preferably, an ozone generator maybe installed and chlorine gas may be provided within the enclosure. Anygasses and most particularly oxygen, that may be present within thecells of the trays can therefore freely diffuse and exchange with thegas in contact with the tray surfaces. With the passage of time, gascontained within the cell structure of the tray walls will therefore bedisplaced with gas in contact with the outer surface of the trays.Preferably, oxygen gas will be substantially removed from the cellstructure. Oxygen will gradually accumulate and the level of “free”residual oxygen remaining in the tube can be monitored by automatic gasanalysis and maintained at a minimum and desired level. This is achievedby extracting gasses from within the tube at a point near an end of thetube while providing an equal quantity of additional oxygen free gasinto the tube at a point near to the opposite end of the tube from theextraction point at the other end of the tube.

Equipment 3302 is a tray sealing apparatus which is arranged to producepackages, including tray, web and perishable goods contents shown asground meat. The perishable goods may be portions of beef, pork or anyother suitable perishable goods.

Referring now to equipment 3318, a representation of an apparatus isshown for producing substantially gas barrier “master containers” from aroll of suitable material 3316. Equipment 3318 may be a Multivac R 530that has been adapted to suit the production system of the presentinvention. Equipment 3320 shown at can be provided for (optionally)locating an oxygen absorber into each master container with the retailpackages before sealing a barrier lid to the master container. Thebarrier lid material 3322 includes a roll of the barrier plastics lidmaterial.

Apparatus 3334 shown in FIG. 222 represents a typical carousel stylevacuum packing machine, such as an “Old Rivers” equipment that has 8vacuum chambers fitted thereto. The carousel style vacuum packingmachine, 3332, is shown fitted with 8 vacuum chamber assemblies similarto that as shown in FIG. 223 and described herein. Referring now to FIG.223, a closed vacuum chamber 2700 including upper vacuum chamber 2702and lower vacuum plate 2704 is shown. A rack 2700 with 2708 trayscontaining perishable goods, red meat, are shown inside closed vacuumchamber 2700. An evacuation port 2710 in direct communication with asource of vacuum is provided. A switch is attached to the vacuum sourceso as to provide on/off control. Two continuous and concentric ‘O’ rings2712 are located between the edges of 2702 and 2704 and spaced apartproviding a space 2714 therebetween. The distance between ‘O’ rings isarranged such that when multiplied by the length of space 2714 the totalprojected area between the concentric ‘O’ rings can be calculated. Totalprojected area shall therefore be equal to PI×‘L1’. When a vacuum isapplied to port 2710, the closing force created between 2702 and 2704can be determined. Assuming that vacuum can be represented in terms of80% of atmospheric air pressure, at approximately 14 psi, then thechamber total closing force, in pounds, would be equal to DI×LI×0.8×14.A gas or blend of desired gasses can be provided within the closedvacuum chamber at a pressure above atmospheric pressure which willprovide a chamber opening force. However, in this arrangement, theclosing force can be arranged to exceed the opening force therebyproviding a method of maintaining a pressure with the closed chamber ata level above that of the prevailing atmospheric air pressure while theclosed vacuum chamber remains closed due to the closing force provided.A further evacuation port 2716 is provided in 2702 and a gassing port2718 is provided also. The upper vacuum chamber 2702 is arranged so thatit can be lifted vertically upward and away from 2704 allowing removalof the rack with trays and another rack with trays can be placed thereinsuch that a continuous production process can be undertaken. The uppervacuum chamber 2702 and the lower vacuum plate 2702 may be arranged withclamping and structural supports so as to allow an increase of gaspressure to gas provided therein to any desired pressure such as 500 psior more.

Perishable goods are located in an EPS (foamed polystyrene) tray withinherent or enhanced gas permeability. A gas permeable web is positionedabove the EPS tray. The web has adhesive applied to the region of theweb that will come into contact with flanges of the tray so as toprovide a seal between web and tray. The web is then sealed to theflanges of the tray. The flange of the tray may be compressed as shownto provide improved structural integrity and strength.

The EPS tray with inherent or enhanced gas permeability can quicklytransfer, remove and exchange substantially all oxygen gas from foamcells during “carousel evacuation and gassing process”.

The web may be printed on one or both sides with panels that can be seenfrom the upper side after sealing to the tray. A bar code can be appliedto label on the underside of the package. The bar code can include codeinformation such as the specific weight of tray contents, date packagedand type of content goods. Information can be read by a scanner at anytime after packaging and converted to consumer readable information thatcan be printed by, for example, ink jet printers onto the panel prior toretail display.

A device to cause oscillation of gas pressure within the chamber at afrequency that will cause improved and more rapid exchange of air andoxygen contained within cells of EPS tray with desired gas provided inchamber, can be provided. Furthermore, the oscillation of gas pressurewithin the chamber, can cause the permeable web to raise and lower andprovide a space between the web and upper surface of the goods therebyallowing the gas provided in the chamber to directly contact the traycontents beneath the web. Oscillation can also provide improved contactwith the goods and enhanced absorption of the gasses by the goods. Theoscillation may be set at a range of gas pressures that are above orbelow prevailing atmospheric pressure. The gas may include othersubstances in vapor, atomized or powder form and the composition may beselected and include the most suitable blend of one or more of thefollowing: nitrogen, oxygen, argon, carbon dioxide, hydrogen, krypton,neon, helium, xenon, O₃, F₂, H₂, O₂, KMnO₄, HClO, ClO₂, Br₂ and I₂.

A desirable blend of gasses such as carbon dioxide and ozone can beprovided within the closed chambers 2702 and 2704 with the rack withtrays contained therein.

Referring now to FIG. 223, racks with trays can be automatically loadedinto open vacuum chambers 3332 which are then closed. A vacuum source isthen applied to port 2710 and a desired gas provided into closed vacuumchambers after removal of atmospheric air there from. The carousel isrotated, intermittently, in the counterclockwise direction shown in FIG.222 and stopped such that after each vacuum chamber assembly 3332 hasfully traveled around the perimeter of the carousel the rack with trayscan be automatically removed from each vacuum chamber and replaced withanother. Therefore a continuous and automatic process of treating trayscontaining perishable goods with desired gasses can be provided.

Referring now to equipment 3326, a diagrammatic representation of anautomatic carton erecting, filling and sealing equipment is shown. Asupply of cartons is also shown as 3324.

Referring now to equipment 3328, a representation of an automatic cartonpalletizer, such as model FL 100 manufactured by Columbia Machine, Inc.,Vancouver Wash., is shown. The palletizer is arranged to automaticallypalletize finished cartons of packaged perishable goods with a supply ofempty pallets 3330. Finished cartons can be automatically transferredfrom equipment 3326 to the palletizer 6.

Equipment 3334 is a representation of equipment configured to locatetray flange covers prior to loading of the perishable goods into thetray. The flange covers are described in Australian patent applicationPM8415. Equipment 3308 is a representation of a section of the packagingequipment that is exposed as require to facilitate efficient loading ofthe perishable goods into the trays. Equipment 3310 is a representationof equipment configured to remove tray flange covers and as generallydescribed in Australian patent application PM8415. Equipment 3306 is arepresentation of the direction of flow of an alternative perishablegoods to be optionally loaded into the trays.

Equipment 3336 is a representation of equipment configured to receive,grind, condition and process meat and other similar perishable goodslike the one shown in FIG. 186. Equipment 3340 is a meat grinder.Equipment 3342 is a pressure vessel. Equipment 3344 is a secondary meatgrinder. Equipment 3346 is a pressure vessel. Equipment 3338 representsthe perishable food item, such as portions of meat, that is to beprocessed and packaged. Equipment 3304 is a diagrammatic representationof equipment configured to locate tray flange covering members prior toloading of the perishable goods into the tray. Equipment 3308 is adiagrammatic representation of a section of the packaging equipment thatis exposed as require to facilitate efficient loading of the perishablegoods into the trays. Equipment 3312 is a representation of a roll ofplastics lid material intended for sealing to flanges of the trays afterperishable goods have been placed therein. Equipment 3314 is arepresentation of an optional feature and equipment for locating labelsonto the underside or, after adjustment, upper side of the retailpackages after sealing of lid material to flanges of the trays.Equipment 3318 is a representation of an apparatus for producingsubstantially gas barrier “master containers” from a roll of suitablematerial 3316, locating an optional oxygen absorbing material into eachmaster container with the retail packages and sealing a lid to themaster container that is unwound from a roll of plastics lid materialshown as 3322. Equipment 3334 is a representation of a typical carouseltype vacuum packaging machine that has been modified according to thedescription provided herein, and located adjacent to both packagingequipment items 2 and 3, so as to facilitate easy transfer of finishedpackages therebetween. Equipment 3332 is one of 8 vacuum chambersmounted to the carousel and as shown in FIG. 223. Equipment 3326 is arepresentation of an automatic carton erecting, filling and sealingequipment with a supply of cartons 3324. Equipment 3328 is arepresentation of an automatic palletizer.

Equipment 3300 is a representation of equipment configured to exchangeair and more particularly, atmospheric oxygen, contained within the cellstructure of foamed polystyrene trays (EPS trays) and foamed polyestertrays (FP trays). FIG. 240 shows a cross-sectional side view of half ofthe arrangement and FIG. 241 shows a cross-section across the full widthof the arrangement, through parts of a preferred apparatus andpackaging.

Equipment 3350 is a diagrammatic representation of an alternativeequipment configured to exchange air and atmospheric oxygen, containedwithin the cell structure of foamed polystyrene trays (EPS trays) andfoamed polyester trays (FP trays).

Thermoforming Apparatus

Referring now to FIG. 224, a plan view of equipment layout according tothe present invention is shown that can be used to produce traysconstructed according to this invention.

The equipment layout is shown in a convenient arrangement for theefficient production of the trays. Primary extruder 4600 is arrangedadjacent to secondary extruder 4602 in a normal condition for productionof expanded polystyrene foam sheet. Direction of flow is shown travelingtoward wind-up mechanism 4604 with spool 4606 attached thereto. A rollof EPS sheet material 4608, is shown adjacent to tube 4610. Tube 4610follows a path that is conveniently arranged parallel with tube 4612. Across-section through tube 4610 is shown in FIG. 225. Tube 4610 extendsto a point of termination adjacent to thermoforming machine shown as4614. A second EPS foam extrusion system with primary extruder 4616 andsecondary extruder 4618 is located adjacent to the first EPS foam sheetextrusion system 4600 and 4602. Second extrusion system extrudes sheetin direction of flow as shown and toward winder 4620, spool 4622 androll 4624 adjacent to the entry end of tube 4612. The construction oftube 4612 can be identical to tube 4610. Tube 4610 and tube 4612 areparallel to each other and follow a concentric path such that 4612terminates at an end in close proximity to thermoforming machine 4626.Tubes 4610 and 4612 follow parallel and concentric paths that spiralupwardly thereby providing an extended length of tubes 4610 and 4612 andcontained within a convenient area.

Referring now to FIG. 225, a section through tube 4612 is detailed.Spool 4606 can be seen inside tube 4612 resting on belt 4628 and belt4630. Belt 4628 and belt 4630 are held taught and arranged to engagewith drive sprockets conveniently located so as to engage the belts.Belts can, thereby, carry spool 4606. Carrying members extend throughoutthe full length of tubes 4610 and 4612 thereby carrying spools 4606through tube 4612 and 4610. A dish 4632 is mounted to a pneumaticcylinder 4634 such that when extended the dish can elevate the spool4606 upwardly so as to lift the spool away from driving belts 4628 and4630. Tube 4612 is shown mounted directly onto a floor, however the tubecan be elevated above the floor by suitable frame members. Gas 4636 isprovided in tube 4612, gas may be nitrogen gas. A three dimensionalsketch of spool 4606 is shown with roll of material 4612 wound thereon.Spools 4606 can be loaded into the entry end of tubes 4612 and 4610which are conveniently located adjacent to the winding members attachedto foam extrusion equipment. Spools can be carried through tubes 4610and 4612 on belts 4628 and 4630 that may be operating continuously. Dish4632 is located conveniently between belt 4628 and belt 4630. Dish 4632and spool 4606 can thereby be elevated, by activating pneumaticcylinder, upwardly and away from contacting belts 4628 and 4630.Pneumatic cylinder 4634 with dish attached thereto may be provided insections that extend throughout the full length of tubes 4610 and 4612.By operating belts 4628 and 4630 with forward driving motion andpneumatic cylinder 4634 and dish, spools 4606 can be carried throughtubes 4610 and 4612 according to demand.

Preferably, tubes 4610 and 4612 can be flooded with a suitable gas suchas nitrogen or a blend of gasses including argon, carbon dioxide,nitrogen and a quantity of oxygen that does not exceed about 5% and isnot less than about 1000 PPM of blend of gasses, through ports 4640 and4612. Spools with rolls of EPS foam material can be stored in tubes 4610and 4612 for a period of time as may be required in the normal aging ofEPS foam material. This period of time may be in the order of twelvehours and accordingly the length of tubes 4610 and 4612 will be arrangedso as to accommodate sufficient spools of material required forproduction of trays and also allowing for the twelve hour residence timeas required. After storing the spools 4606 in tubes 4610 and 4612quantities of spools can be removed from the exit end of the tubesadjacent to the thermoforming machines. Spools can be loaded onto thethermoforming machines and thermoformed trays with flaps can bemanufactured, as required.

Referring now to FIG. 227, a cross-section through a thermoformingmachine oven is shown. The oven includes a substantially sealed andenclosed rectangular tube with heaters 4633, 4635 arranged above andbelow EPS sheet 4631 that can be carried therethrough. The EPS sheet canbe fed into the oven through a slot that is slightly larger than across-section through the EPS sheet. Tube 4646 is attached to the undersection of the oven and tube 4644 is attached to the upper section ofthe oven. Gas can be provided at a pressure above the ambientatmospheric pressure, from a “nitrogen generator” directly into tube4646. Gas can be extracted from tube 4644 that follows a path along path4648 and through cooler 4650. Tube 4644 delivers the gas and anadditional quantity of air along tube 4644 and into the nitrogengenerator. The nitrogen generator generates nitrogen gas by way ofseparating oxygen from air and allowing only nitrogen to pass into andthrough tube 4646. Gas may be provided into tube 4646 directly from tube4644 if required.

Referring again to FIG. 224, a plan view of tubes 4660, 4662, 4664, 4666are shown passing through a wall. The tubes may be filled with asuitable gas. Fully formed trays with flaps can be loaded into the tubesfor direct transfer and use on packing machines.

Preferably, the thermoforming apparatus herein described can beincorporated into the plant layout schematic of FIG. 222. Referring nowto FIG. 228, a slight modification to a previous equipment plan is shownfor producing trays according to the present invention. Equipmentincludes four tubes 4700, 4702, 4704, and 4706. Each item is arranged toform a horizontally displaced, rectangular or square tube with doors ateach end. Each tube is conveniently positioned so that access to doorsat each end of tube can be accessed for loading of packaging materialsinto tube. When the doors are shut, the tube is sealed to provide afully enclosed container or enclosure in which the EPS or FP trays canbe stored. Conveniently located ports are provided into the walls of thetube such that suitable gasses can be introduced as required within thetube thereby displacing substantially all atmospheric air and mostparticularly atmospheric oxygen there from.

Each tube is loaded with quantities of EPS and/or FP trays and doors areclosed to provide a sealed container. Most preferably nitrogen, otherinert and/or any other suitable gasses are provided into the tube so asto displace substantially all air from the interior of the tube andthereby providing a condition where gas is in contact with the surfaceof EPS and/or FP trays. Additionally, an ozone generator may beinstalled and chlorine gas may be provided within the enclosure. Anygasses and most particularly oxygen, that may be present within thecells of the trays can therefore freely diffuse and exchange with thegas in contact with the tray surfaces. With the passage of time, gascontained within the cell structure of the tray walls will therefore bedisplaced with gas in contact with the outer surface of the trays. Mostimportantly oxygen gas will be substantially removed from the cellstructure. Oxygen will gradually accumulate and the level of “free”residual oxygen remaining in the tube can be monitored by automatic gasanalysis and maintained at a minimum and desired level. This is achievedby extracting gasses from within the tube at a point near an end of thetube while providing an equal quantity of additional oxygen free gasinto the tube at a point near to the opposite end of the tube from theextraction point at the other end of the tube.

Open and Closed Cell Structures

Referring now to FIGS. 229-237, cross-sectional and enlarged views ofexpanded polystyrene (EPS) foam sheet are shown, wherein FIG. 229 showsa cross-section through a portion of co-extruded EPS foam includingthree layers 4500, 4502 and 4504. FIG. 230 shows a cross-section througha portion of extruded EPS foam sheet including three layers 4506, 4508and 4510 and wherein layers 4506 and 4510 include skin similar to thesection shown in FIG. 233.

Referring to FIG. 229, outer layers 4500 and 4504 sandwich an innerlayer 4502. Outer layers 4500 and 4504 include closed cell EPS foam asshown in FIG. 232. “Closed cell” EPS foam describes a physical conditionwhere the cells or bubbles, that are filled with gas, generally includeenclosed spherical spaces where the cell, bubble or sphere is notfractured and therefore any gas contained therein can enter or exit thespheres by diffusion through the spherical wall only and not throughfractures or openings in the sphere wall. FIG. 232 shows a grouping ofcells or bubbles that contain a gas which may be air. Layer 4502includes a layer of open celled EPS foam as shown in FIG. 235. “Opencell” EPS foam is a physical condition where most cells or bubbles arefractured and allow gas and other matter to invade the internal space ofthe open cells readily. Production of open cell EPS foam can be effectedby introducing contaminants into the polystyrene melt prior to foaming.The contaminants may include a surfactant to enhance liquid absorbingproperties, can cause fractures in the cell walls to appear. Closed cellEPS foam is produced by ensuring that there are no contaminants in thepolystyrene melt prior to foaming. Closed cell foam generally provides amore mechanically stable and rigid structure than does open cell foam.Therefore in order to produce a more mechanically stable and rigidpackaging tray, closed cell polystyrene is a preferred constructionmaterial. However closed cell EPS foam resists absorbing liquids such asblood, water and purge. In order to produce a superior EPS foampackaging material that has both liquid absorbing and structurally soundproperties use of a combination of both types of open and closed cellfoam is preferable. A preferred material would include three layers ofco-extruded multi-layer foam sheet where layers 4500 and 4504 includeclosed cell EPS foam and layer 4502 includes open cell EPS foam.

Referring now to FIG. 230 a cross-section through a preferred materialis shown where a three layer material includes two outer layers 4506 and4510 and a center layer 4508. Layers 4506 and 4510 are similar andinclude a skin that can be induced by exposing a mono extruded layer ofEPS foam, before the foam has cooled and solidified, to relatively coolair applied thereto under regulated pressure. By applying the regulatedcompressed air in this way a skin can be formed by deflating the open orclosed cell structure at one or both surfaces of the EPS sheet. Thelayer 4508 includes a layer of open cell EPS foam.

Referring now to FIG. 231, the closed cells are shown schematically, asbeing exposed to gas pressure that is higher than gas pressure insidethe closed cells. Enlarged view of closed cell FIG. 237 shows a ratio ofa pressure differential where P equals the external gas pressure and P1the closed cell internal gas pressure. FIG. 234 shows a grouping ofclosed cell EPS foam cells where the internal pressure P1 is greaterthan the external gas pressure P.

The present invention to provides a method to substantially removeoxygen gas that may be retained within the cell structure of the EPSfoam packaging materials and to also reduce the amount of oxygen and/orslow the rate at which oxygen may re-enter the cell structure afterremoval from storage and processing in a suitable gas. The followingsteps disclose a method that can be used to achieve this condition. Anyor all of the following steps may be effected in the sequence shown orany other sequence that enhances the most efficient and rapid removal ofundesirable gasses, including oxygen, from the structure of thepackaging materials:

Place a quantity of EPS foam packaging materials, such as trays withflaps, in a gas tight and sealed pressure chamber, with evacuation andgassing ports therein and valves attached so as to allow evacuation andgassing, with suitable gas, of the pressure chamber as desired.

Provide a vacuum inside the pressure chamber, by lowering gas pressuretherein, and maintain for a period of time so as to enhance the removalof oxygen from the structure of the packaging materials in a desiredmanner.

Introduce a suitable gas into the pressure chamber at an initialselected and suitable pressure that may be below ambient atmosphericpressure.

Maintain the selected and suitable pressure for a period of time thatenhances the removal of oxygen from the structure of the packagingmaterials in a desired or optimized manner.

Progressively increase the pressure of the suitable gas in the pressurechamber, in a continuous or intermittent manner, over time, until thegas pressure is above atmospheric pressure.

Maintain the gas pressure for a period of time that enhances the removalof oxygen from the structure of the packaging materials in a desired oroptimized manner.

By heating and/or cooling apparatus, maintain the temperature of thepackaging materials and the suitable gas in the pressure chamber, at atemperature that enhances the removal of oxygen from the structure ofthe packaging materials in a desired or optimized manner.

During the process, described above, exchange the suitable gas, whilemaintaining the suitable gas pressure in the pressure chamber asrequired, which can continuously occur during the process, at a suitablerate of exchange to ensure that any undesirable gas, including oxygen,that may become present in the suitable gas, is substantially removedfrom within the pressure chamber.

Remove the packaging materials from the pressure chamber and allow thepackaging materials to physically expand as can occur due to a higherrelative gas pressure that may exist in the closed cell structure of theEPS packaging materials.

Maintain the packaging materials at a suitable temperature for asuitable period of time, after removal from the pressure chamber.

The steps disclosed above may be repeated, sequentially or otherwise andin a manner that provides an efficient process to remove undesirablegasses from the structure of the packaging materials and to enhance theexpansion of the packaging materials in a desired manner.

In this way oxygen gas can be removed, from within the open and closedcell structure of EPS foam material, and replaced with the suitable gasat a pressure above atmospheric pressure. The packaging materials canthen be used for packaging. The higher pressure within the closed cellstructure can gradually equilibrate with that of the prevailing ambientatmospheric air pressure, however during this equilibration period therate of re-entry of atmospheric oxygen into the structure of thepackaging materials can thereby be reduced.

In another preferred embodiment, adhesives such as any suitable bondingmedium may be applied to surfaces of the flaps of tray and the traywalls and base by any suitable “ink jet” apparatus. Furthermore, coloredgraphic printing and any desired information can be printed and/orapplied to any desired surfaces of the tray and flaps by any suitable“ink jet” apparatus. The “ink jet” equipment is manufactured by severalcompanies such as Hewlett Packard, Xerox, SciTex, Marconi/Video Jet andothers. The equipment can be arranged to apply inks, lacquers andadhesive materials as required by, for example, arranging the ink jetequipment adjacent to a conveyor that can transport the trays with flapsat a suitable speed and in such a manner as to allow application of theinks and other materials to the trays and flaps, as required. Theconveyor may be arranged adjacent to and integrated with thermoformingmachinery such that immediately after producing trays with flaps, thetrays can be automatically transferred onto the conveyor. The conveyorcan be arranged to carry trays with flaps at a controlled speed and asrequired to allow application of inks and any suitable materials theretoby ink jet printer.

Tray Treatment Method and Apparatus for the Removal of Oxygen

Referring now to FIG. 238, details of an apparatus for storing foam (EPSor polyester foam) trays, for exchanging gas in cells with a preferredgas is shown. This apparatus provides a method to substantially removeany residual oxygen that may be retained in the cell structure of EPSpackaging materials intended for use in packaging fresh red meats in a“low oxygen” master container, case ready packaging system. The methoddisclosed herein can provide a process to remove and replace theresidual oxygen, with a desired gas, more rapidly than occurs when theEPS packaging materials are stored in a chamber containing desired gasin a static condition at ambient atmospheric pressure. The apparatusincludes a rectangular or suitably profiled tube 4200. The tube 4200 isarranged to have two open ends 4202 and 4204, one at each end of thetube 4200. The tube is provided with evacuation port 4206 and gas entryport 4208. The tube can be filled with precut foam (EPS) trays withflaps, or sheets of foam 4210. The tube can be arranged to have asuitable length and be configured in such manner as to allow automaticloading from the trim press of a suitably modified thermoforming andtray trimming apparatus. The tube can further be arranged so as to allowautomatic removal of one tray with flaps at a time for subsequentautomatic processing of the tray with flaps to form a finished tray withbonded and sealed flaps.

Open ends 4202 and 4204 can be arranged to mate with covering caps (notshown) in such a manner as to completely enclose the tube and provideairtight seals at both open ends. The completely enclosed tube 4200 canthereby provide a vacuum chamber containing the trays with flaps suchthat when a vacuum source is connected to evacuation port 4206substantially all air contained therein can be removed. After evacuationof the air from the tube, the vacuum within the tube can be maintainedfor a period of time, the period of time being sufficient to allowremoval of substantially all retained air and oxygen from the cellstructure of the trays with flaps. After removal of substantially allair and oxygen from within the cell structure, a suitable gas such asnitrogen or carbon dioxide can be provided into the tube via gas entryport 4208. The gas can be retained within the enclosed and sealed tube4200 for a period of time sufficient to allow the cell structure tobecome filled with the suitable gas. Alternatively, evacuation of airfrom within the tube can be adjusted to provide a remaining gas or airpressure therein at any pressure between zero and ambient atmosphericair pressure and suitable gases can be provided in the tube so as toblend with any remaining air contained therein after evacuation to adesired pressure. Such process of evacuation and gassing can be repeatedin accordance with an optimized process that will result in the mostrapid exchange of retained oxygen in the cell structure with a desiredgas.

In another preferred embodiment, the evacuation port 4206 may beprovided in the sealing cover over open end 4204 and the gas entry port4208 may be provided in the sealing cover over the open end 4204. Thepreferred embodiment can thereby provide an arrangement where a vacuumsource can be attached to the evacuation port and a gas source can beattached to gas entry port and provide a continuous flow of gas throughthe tube from one end to the other so as to contact the surface of thetrays with flaps contained herein. The pressure of the gas flowingthrough the tube can be arranged at a level most suitable to achieve themost rapid removal of air and oxygen that may be contained within thecell structure of the trays with flaps and thereby exchange the oxygenwith the desired gas.

Referring now to diagram FIG. 238, details are shown of an apparatus forstoring foam (EPS or polyester foam) trays, for exchanging gas such asoxygen that may be contained in the cell structure of the trays, with apreferred gas. The apparatus removes any residual oxygen that may beretained in the cell structure of the EPS trays that are intended foruse in packaging fresh red meats in a “low oxygen” master container,case ready packaging system. The apparatus and method disclosed hereincan provide a process to remove and replace the residual oxygen, with adesired gas, more rapidly than occurs when the EPS packaging materialsare stored in a chamber containing desired gas in a static condition atambient atmospheric pressure.

The apparatus includes a rectangular or suitably profiled tube 4200. Thetube is arranged to have two open ends 4202 and 4204, one at each end ofthe tube. The tube is provided with evacuation port 4206 and gas entryport 4208. The tube can be filled with precut foam (EPS) trays withflaps, or sheets of foam 4210. The tube can be arranged to have asuitable length and be configured in such manner as to allow automaticloading from the trim press of a suitably modified thermoforming andtray trimming apparatus. The tube can further be arranged so as to allowautomatic removal of one tray with flaps at a time for subsequentautomatic processing of the tray with flaps to form a finished tray withbonded and sealed flaps as described above.

The open ends 4202 and 4204 can be arranged to mate with covering caps(not shown) in such a manner as to completely enclose the tube andprovide airtight seals at both the open ends. The completely enclosedtube can thereby include a vacuum chamber containing the trays withflaps such that when a vacuum source is connected to evacuation port4206 substantially all air contained therein can be removed. Afterevacuation of the air from the tube, the vacuum within the tube can bemaintained for a period of time, the period of time being sufficient toallow removal of substantially all retained air and oxygen from the cellstructure of the trays with flaps. After removal of substantially allair and oxygen from within the cell structure, a suitable gas such asnitrogen or carbon dioxide can be provided into the tube via gas entryport 4208. The gas can be retained within the enclosed and sealed tubefor a period of time, which may be 1 to 2 hours, sufficient to allow thecell structure to become filled with the suitable gas. In a preferredprocedure, the air will be substantially evacuated through theevacuation port 4206 and then a gas such as nitrogen will be introducedthrough port 4208 at a suitable low pressure. The gas will be held atthe suitable low pressure for a period of time and then, the lowpressure of the gas will be gradually increased, over a period of time,and until the gas pressure is increased to a maximum gas pressure aboveambient atmospheric pressure. The maximum gas pressure may be 60 psi ormore.

Alternatively, a partial evacuation of air from within the tube 4200, toa level that does not completely evacuate the tube but lowers the airpressure therein to a pressure above zero and below ambient atmosphericair pressure. A suitable, oxygen free, gas such as nitrogen can beprovided into the tube, through the port 4208, so as to blend with theremaining air contained therein. This process of partial evacuationfollowed by gassing can be repeated, sequentially until the oxygen gascontained in the EPS cell structure is removed and in an optimizedprocess that will result in the rapid exchange of the retained oxygen inthe cell structure with a desired gas.

In another preferred embodiment the evacuation port 4206 may be providedin the sealing cover over the open end 4204 and the gas entry port 4208may be provided in the sealing cover over the open end 4202. A vacuumsource can be attached to the evacuation port 4206 and a suitable gassource, such as nitrogen or a blend of gasses including argon, carbondioxide, nitrogen and a quantity of oxygen that does not exceed 5% andis not less than 1000 PPM, can be attached to the gas entry port 4208and thereby providing a continuous flow of gas through the tube fromport 4208 to evacuation port 4206 so that the suitable gas contacts thesurface of the trays with flaps contained herein. The pressure of thegas flowing through the tube can be arranged at a level most suitable toachieve the most rapid removal of air and oxygen that may be containedwithin the cell structure of the trays with flaps.

In yet another preferred embodiment, a plurality of the rectangular tube4200, may be conveniently stacked together and located inside a suitablysized vacuum chamber. Substantially all air may be evacuated from withinthe vacuum chamber and held with the vacuum source attached thereto fora period of time sufficient to allow removal of substantially all gasfrom within the expanded polystyrene foam cell structure. A suitablegas, such as nitrogen can then be provided into the vacuum chamber, at apressure equal or greater than ambient atmospheric pressure so as tocompletely fill the vacuum chamber and contact all surfaces of foamtrays in the tubes. After a period of time the plurality of tubes can beremoved from the vacuum chamber.

Referring now to FIG. 239, another embodiment of a rectangular tubehaving top bottom open ends is shown. Preferably, the rectangular tubemay be manufactured from any suitable material such as stainless steelor other plastics material and may be arranged to have any convenientlength. Preferably, the rectangular tube can be manufactured withlongitudinally parallel sides and a cross-section that corresponds withthe cut size of the trays that are shown therein. More specifically therectangular tube will have a cross-sectional opening that is sized so asto be slightly larger that the cut size of the trays contained therein.For example, if the plan, cut size dimensions of the trays is 5 incheslong by 4 inches wide the opening in the rectangular tube will be about5.125 inches long by about 4.125 inches wide.

A gas entry port 3302 is shown located in the wall of the rectangulartube at about equal distance from each end of the rectangular tube. Aplurality of additional gas entry ports may be provided at any suitablelocation in the wall of the rectangular tube. Most preferably, asuitable gas or blend of gasses, such as nitrogen, may be providedinside the rectangular tube through the entry port 3302. The gas may beprovided by an injector into the rectangular tube through one or more ofgas entry ports at a set pressure and volume. Gas may be provided at apressure that is varied by normal methods or alternatively by way of aset pitch sound that may also be varied in a manner to enhance gasexchange. Preferably, length of rectangular tube 3300 can be arrangedsuch that when trays are passed through the rectangular tube, theresidence time of trays within the rectangular tube will be sufficientto allow gas exchange to occur between suitable gas provided through theentry port and into the rectangular tube and gasses such as oxygen thatmay be contained within the cell structure of the trays. Trays may beloaded through an opening at the open tope of rectangular tube andunloaded through the open bottom.

Preferably, rectangular tube is vertically disposed such that gravitywill provide sufficient force to cause the trays to pass through theopening through the rectangular tube, when trays are removed from thebottom of rectangular tube. Alternatively, the rectangular tube may behorizontally disposed and a driver such as an auger (not shown) may beprovided to transfer the trays through the rectangular tube. Preferably,the rectangular tube may be arranged so as to connect with an automatictray dispenser so that trays can be automatically removed, one or moreat a time, and subsequently be positioned onto a packaging machine inreadiness for loading of perishable goods such as fresh red meattherein. A plurality of rectangular tubes may be arranged together in agrouping so as to process a plurality of trays simultaneously.

The rectangular tube can be manufactured to suit trays of any size.

Tray Forming Apparatus

Referring now to FIGS. 240-241 where a cross-section of the tray formingapparatus 2200 is illustrated. The apparatus is intended for used in amethod for removing oxygen gas from the structure of expandedpolystyrene packaging materials that are intended for use in packagingperishable goods that could be deleteriously affected by the presence ofoxygen in quantities that exceed 500 PPM. The method includes but is notlimited to the use of any suitable gas at any suitable pressure arrangedto pass through the packaging materials by providing the suitable gas toone side of the packaging materials at a pressure above what is the gaspressure of any gas that is present on the opposing side of thepackaging materials. The suitable gas will thereby be caused to passthrough the packaging materials and furthermore cause a reduction inoxygen contained in the structure of the packaging materials.

The apparatus includes two parts. The first part shown in FIG. 240 is aside view cross-section with the apparatus in a closed position and atray clamped between an upper chamber 2252 and a lower chamber 2254.FIG. 240 shows half of the apparatus with a center line marked throughwhat would be the center of the apparatus. The other half of theapparatus is a mirror image of the part that is shown. FIG. 241 shows across-section across the entire width of the upper and lower chambers2252 and 2254.

The apparatus 2200 includes an upper and lower chamber which arearranged so as to be moveable toward and away relative to each other,thereby allowing trays to be processed in a continuous mode.

A porous mold 2256, that is profiled to follow the contours of the trayand to neatly fit within the confinement of the chambers 2252 and 2254,is provided and can be fixed to the upper chamber. A gassing port 2258is provided in the lower chamber 2256 and an evacuation port 2260 isprovided in the upper chamber 2252. The porous mold 2256 can bemanufactured from a suitable porous material and may have grooves andslots machined across the surface of the profiled face 2262 that are allconnected to evacuation port 2260, thereby allowing gasses to beevacuated therethrough and through port 2260. The apparatus can beconfigured to accommodate one or more trays, however, for ease ofexplanation the apparatus shown in FIGS. 240-241 preferably accommodatesone tray. A blade 2264 is provided within chamber 2254 which is attachedto a moving member. The blade 2264 can be arranged in a continuouslength to provide a knife edge that follows the perimeter of what willbecome the processed and cut tray. Space is provided between the surfaceof the profiled mold 2256, as shown, providing a space into which asuitable pressurized gas can be provided.

A tray 2268, having extended flanges, 2270, is located on the porousmold 2256 and the chambers 2252 and 2254 are closed so as to clamp theflange ‘TF’ around the full perimeter of the tray. The tray 2270 may bethermoformed from expanded polystyrene and therefore has a porosity andcan therefore allow pressurized gas to pass therethrough. Pressurizednitrogen gas can then be provided into the space through port 2258 at asuitable pressure. A vacuum source can be attached to port 2260. The gasthereby passes through the porous tray walls and can displace oxygen gasthat may be present therein. The pressurized gas can be provided intothe space and passed through the tray porous walls for sufficient timeto displace substantially all oxygen gas that may have formerly beenpresent therein. The blade 2264 with knife edge can be activated andmoved by the moving member 2250 so as to cut through the tray flange2270. Chambers 2252 and 2254 are opened allowing the tray 2268 to beremoved in readiness for additional trays to be processed in a similarfashion as described above. Trays 2268 can be removed and replaced onthe porous mold 2256 in a continuous, intermittent and automaticprocedure. The porous mold 2256 can be interchanged with other moldshaving different profiles to suit other trays of different size andprofile.

Flange 2270 and any other part of the tray 2270 and the flap 2272 may becompressed, as desired, to substantially remove gas from the foam cellsthereby forming a substantially solid section in the tray, flap 2272 andflange 2270 as required. In this way the solid section can be arrangedto provide a continuous solid section around the perimeter of the traysuch that a web of material such as pPVC can be sealed to the solidsection along a strip like path around what will become a perimeter of afinished package. The solid section may be located at the connectionbetween the flap 2272 and the tray 2268 such that the flap 2272 and thetray 2268 can be hinged and folded so as to allow contact of tray flange2270 with the tray 2268.

The apparatus is similar to a standard expanded polystyrenethermoforming machine, where two parallel platens are arranged in closerelative proximity and with a powered device for moving the platenstoward and away from each other. Matched tools including two parts, aretypically mounted onto the platens such that a heated sheet of expandedpolystyrene or other suitable sheet, can be located between the platensand separated matched tool parts. The platens can be moved toward eachother to a position that clamps the heated sheet between the two partsof the matched tool, thereby imparting a three dimensional profile thatcorresponds to the profile of the matched tool, into the sheet. Afterthe sheet cools, the platens and the matched tool open and the profiledsheet can be removed automatically to allow the positioning of anothersheet of EPS sheet therebetween. The EPS sheet is typically arranged ina continuous web.

As disclosed in the aforementioned description, trays can be processedin an automatic and continuous mode, such that any oxygen gas that maybe retained in the EPS cell structure can be substantially removed andreplaced with a desired gas such as nitrogen. The method and apparatusdescribed herein, can also be incorporated into standard thermoformingmachinery used for production of thermoformed EPS trays.

In a preferred embodiment, the trays with flaps can be produced on anautomatic apparatus that heats a web of EPS sheet in an oven thatsubstantially excludes oxygen so as to ensure that during any expansionof the EPS sheet during heating, immediately prior to thermoforming ofthe EPS sheet, oxygen gas will be substantially prevented from enteringinto the cell structure of the EPS sheet. This can be achieved byproviding a suitable gas such as nitrogen in the oven during the heatingof the EPS sheet, the nitrogen gas being in direct contact with thesurfaces of the EPS sheet. The EPS sheet can then be transferreddirectly into a forming station that is arranged to substantiallyexclude oxygen gas therefrom and furthermore, apply pressurized nitrogengas to one side of the tray with flaps during the forming process andcausing the nitrogen gas to pass into and through the tray and flapsduring the forming process. Adhesive or solvent can then be applied toselected areas of the flaps and the tray, either before or aftertrimming the tray with flaps from the sheet of EPS material. Thenautomatically fold the flaps and mechanically apply sufficient pressureto the flaps to hold against the walls of tray and cause bonding betweenthe flap and the tray at desired regions therebetween.

A preferred embodiment includes, but is not limited to automatically ormanually performing the following steps:

1. Providing a tray that may be thermoformed from expanded polystyrene(EPS) with flaps as shown in diagram. The tray having dimensions thatwill provide for the efficient use of the internal capacity of typical,refrigerated transport vehicles.

2. Exposing the tray to a gas that excludes oxygen and allowing the gasto exchange with any gasses contained within the cells of the EPSthereby substantially displacing any atmospheric oxygen from the cells.

3. Providing perishable goods onto the base of the tray. The perishablegoods having been treated and processed to substantially eliminate anybacteria thereon.

4. Sealing a gas permeable material such as pPVC to the flanges of thetray.

5. Folding and then sealing the flaps to flanges of the tray.

6. Placing the tray or a plurality of similar trays into a gas barriermaster container.

7. Displacing substantially all atmospheric gas, and particularlyatmospheric oxygen, within the master container, with a desired singleor blend of desired gasses.

8. Sealing a lid over the opening in the master container to form ahermetically sealed package containing the trays with perishable goodsand desired gas.

9. Placing the master container inside a carton such as can bemanufactured from corrugated cardboard and enclosing the mastercontainer.

10. Locating a plurality of the closed cartons onto a standard (GMAspecified) pallet (Dimensions of 40″×48″) so as to maximize theefficient use of the area provided by the pallet.

Tray Materials of Construction

A multi-layer, co-extruded plastics sheet product extruded through anannular die is disclosed, including substantially amorphous polyesterpolymers, with additives, similar, but not exclusively, to thestructures shown in FIGS. 242-240 where at least one of the layers is afoamed polyester and where at least one or more other layers includes atleast about 30% regrind material derived from the skeletal scrapremaining after production of thermoformed trays from the sheet, withthe balance of the regrind layer including a chosen virgin amorphouspolyester polymer.

FIG. 242 shows a multilayer coextruded plastic sheet constructedaccording to the present invention including five layers. Beginning fromthe uppermost layer 2900, the co-extruded first layer 2900 includes amix of blended components about 50% Eastman 6763 and about 50% Eastman19411. The first layer 2900 is about 0.001 inches thick. The secondco-extruded layer 2902 includes Eastman 9921 and is about 0.0025″ thick.The third co-extruded layer 2904 includes a blended mix of foamedEastman 9663 and Eastmann additive G4ZZZ-3AZZ, and is about 0.012″thick. The fourth co-extruded layer 2906 includes Eastman 9921 and isabout 0.0015″ thick. The fifth layer 2908 includes regrind materialrecovered from tray thermoforming processes, and is about 0.002″ thick.The overall thickness of the sheet material shown in FIG. 242 is about0.018″ thick.

FIG. 243 shows a multilayer coextruded plastic sheet constructedaccording to the present invention. The sheet material includes fourlayers. Starting from the uppermost layer, the first co-extruded layer2909 includes a blended mix of about 60% Eastman 9921 and about 40%Eastman 6763. The first layer 2909 is about 0.002″ thick. The secondco-extruded layer 2910 includes a blended mix of foamed Eastman 9663 andEastman additive G4ZZZ-3AZZ, and is about 0.011″ thick. The thirdco-extruded layer 2912 includes regrind material derived from skeletalscrap recovered from the tray thermoforming process, and is about0.0015″ thick. The fourth co-extruded layer 2914 includes a blended mixof about 60% Eastman 9921 and about 40% Eastman 6763 and is about 0.002″thick. The overall thickness of the material shown in FIG. 243 is about0.0165″ thick.

FIG. 244 shows a multilayer, coextruded plastic sheet including threelayers. Beginning with the uppermost layer, the first co-extruded layer2916 includes a blended mix of about 20% Eastman 6763, 50% Eastman 9921,and about 30% of regrind material. The first layer 2916 is about 0.0025″thick. The second co-extruded layer 2918 includes a mix of blended andfoamed Eastman 9663 and Eastman additive G4ZZZ-3AZZ. The second layer2918 is about 0.011″ thick. The third co-extruded layer 2920 includes amix of about 20% Eastman 6763, about 50% Eastman 9921, and about 30%regrind material. The third layer 2920 is about 0.0025″ thick. Theoverall thickness of the sheet material of FIG. 244 is about 0.016″thick.

FIG. 245 shows a multilayer, coextruded plastic material constructedaccording to the present invention. The sheet material includes fivelayers. Beginning with the uppermost layer, the first co-extruded layer2922 includes a blended mix of about 50% Eastman 19411 and about 50%Eastman 6763. The first layer 2922 is about 0.0015″ thick. The secondco-extruded layer 2924 includes a blended mix of about 90% Eastman 9921and about 10% of regrind material derived from skeletal scrap recoveredfrom the tray thermoforming process. The second layer 2924 is about0.006″ thick. The third co-extruded layer 2926 includes a blended mix ofabout 90% of regrind material derived from skeletal scrap from the traythermoforming process and about 10% of Eastman 9921. The third layer2926 is about 0.003 inches thick. The fourth co-extruded layer 2928includes a mix of blended and foamed Eastman 9663 and Eastman additiveG4ZZZ-34ZZ. The fourth layer 2928 is about 0.019 inches thick. The fifthco-extruded layer 2930 includes a mix of about 90% Eastman 9921 andabout 10% of regrind material. The fifth layer 2930 is about 0.0005″thick. The overall thickness of the sheet material of FIG. 245 is about0.03″ thick.

FIG. 246 shows a multilayer, coextruded plastic sheet materialconstructed according to the present invention. The sheet materialincludes five layers. Beginning with the uppermost layer 2932, the layer2932 includes about 50% blended Eastman 6763 and about 50% Eastman19411. The first co-extruded layer 2932 is about 0.0015″ thick. Thesecond co-extruded layer 2934 includes about 10% blended Eastman 9921and about 90% regrind materials derived from skeletal scrap recoveredfrom tray thermoforming process. The second layer 2934 is about 0.0015″thick. The third co-extruded layer 2936 includes blended and foamedEastman 9663 and Eastman additive G4ZZZ-3AZZ. The third layer 2936 isabout 0.010″ to about 0.019 thick. The fourth co-extruded layer 2938includes about 10% blended Eastman and about 90% regrind materialsderived from skeletal scrap recovered from tray thermoforming process.The fourth layer 2938 is about 0.0015″ thick. The fifth co-extrudedlayer 2940 includes about 50% blended Eastman 6763 and about 50% Eastman19411. The fifth layer 2940 is about 0.0015″ thick. The overallthickness of the sheet material of FIG. 246 is about 0.016″ thick.

Tray Materials of Construction

Referring now to FIG. 247, a cross-sectional view through a portion ofmaterial constructed according to the present invention is shown.Polyester sheet material is co-extruded in a three layer constructionhaving two outer layers 2000 and 2002 of Eastman APET 9921 (about 0.002″thick, each) and an inner layer 2004 of foamed Eastman 9663 with anEastman recommended quantity of Eastman melt strength enhancerG4ZZZ-3AZZ. Inner layer 2004 is about 0.015″ thick. Inner layer 2004 isfoamed with a suitable quantity of nitrogen gas, substantially excludingair from foam cells. The total thickness of co-extruded sheet isapproximately 0.019″ thick. The gas barrier properties of the outerlayers of Eastman 9921 are such that air will be substantially preventedfrom permeating into the inner layer of foamed polyester. Sections ofthe material have been compressed so as to solidify the inner layer offoamed Eastman Polyester 9663 with the melt strength enhancer. Bothedges of co-extruded sheet are sealed together, by any suitable sealer,preferably immediately after co-extrusion and prior to winding onto aroll. Sealing edges substantially prevents air from permeating intoinner layer 2004 of foamed polyester. Material is wound onto a roll andis then stored, most preferably in a temperature controlled storage areaand at a temperature below 10° C. Following storage, the roll ofco-extruded polyester material is substantially converted into trays ofa desired profile and size by a thermoforming apparatus such as shown inFIG. 248 where a cross-section through such a tray is shown.Thermoforming apparatus includes a typical method of pre-heating thesheet, clamping convenient rectangular sections of the heated sheet andvacuum (or pressure) forming the sheet onto a suitable tray formingmould, however, at the moment of thermoforming and prior to cooling ofthe sheet, a suitably shaped tool, that may also be heated to a desiredtemperature, can be pressed against the flange regions, or edge of theflange regions, of the trays during the forming process and therebycompress the flanges. Most desirably the compression of the flanges willcause substantially all gas to be expelled from the inner layer offoamed polyester in the flange regions only. Said trays are severed, bya cutting member, from the sheet of material such that the edges of theflange are substantially sealed together. Such a process can provide atray with gas barrier outer layers of polyester and an inner foamedlayer of polyester such that the inner layer is substantially preventedfrom direct contact with ambient air. In this way ambient air will besubstantially prevented from permeating into the inner layer and alsoproviding a gas barrier to substantially prevent nitrogen gas within thefoam cells from escaping and exchanging with air.

FIG. 249 shows a cross-section of the material showing an upper 2000, aninner 2004, and a lower 2002 layer. The upper layer 2000 is about 0.002″thick, the inner layer 2004 of foam polyester is about 0.15 thick andthe lower layer 2002 is about 0.002″ thick. FIG. 250 shows the materialof FIG. 249 when the material is compressed according to the presentinvention. Outer layers 2000 and 2004 remain substantially about 0.002″thick, but inner layer 2004 has been compressed to about 0.001″ thick.

Tray Rib Forming Apparatus

Referring now to FIG. 251 a tray with ribs formed in accordance withthis invention is shown. The inventor has previously invented a systemwhereby a low oxygen modified wing system including a “master container”(container) with trays therein, is evacuated. During evacuation, allcontents of the container are exposed to a very high level of vacuum,furthermore, the pressure of nitrogen gas, contained within the innerlayer foam cells which is approximately equal to the prevailing ambientatmospheric pressure, will exert an “exploding” pressure against theinner surfaces of the outer layers. Pressure can cause distortionresulting in, at least, partial separation of inner layer from outerlayers. Furthermore, in extreme cases tray walls could rupture and burstopen. Clearly, such an event is undesirable and this present inventionprovides a method, equipment and production of a tray (product), thatcan minimize this undesirable event. By including regions of densematerial, the inventor has discovered that trays can withstand the lowpressure atmosphere used in the above application.

FIG. 251 shows a three dimensional section of a tray that has beenthermoformed from sheets of material similar to those described in thestructures shown in FIGS. 242-246. FIG. 253 is a view of a sectionthrough a wall of the tray with ribs 2100 provided therein. Referringnow to FIG. 256, an apparatus that can be used to provide ribs 2100 isshown. Ribs can be provided by closing heat bank 2118 onto wall of tray2114 when tray 2114 is supported by pad 2116. Heat bank 2118 can therebyweld/heat seal a portion of the inner surface of the outer layers 2108,2112 to each other after compression of inner layer 2110 foam cells suchthat the outer layers become welded/heat sealed to each other at thepoint of contact. Radius 2106 of ribs 2100 as shown in FIG. 253 can beadjusted and also the distance of pitch from radius to radius can alsobe adjusted by production of equipment providing the desiredadjustments. Adjustments can be made in order to provide for optimizedconfiguration of radius 2106 and pitch such that the exploding effect ofexposure to high vacuum that could otherwise result in the rupturing ofthe tray, as described above can be minimized.

In a preferred embodiment, an apparatus for compressing a web ofmaterial 2124 to provide ribs therein is detailed in FIG. 255. Heatbanks 2120 and 2124 are arranged, as required, in a mechanism so as toenable compressing of material therebetween and thereby bond outer layer2126 and inner layer 2130 together with compressed foamed polyesterlayer 2128 therebetween. A cross-sectional view through a portion ofcompressed material 2124 with an aperture punched therethrough is shownin FIG. 256. Additionally a mechanism for providing perforations in anouter layer of a tray wall thermoformed from the material shown in FIG.247, is also detailed in FIG. 257. Perforations 2136 can be provided toallow communication and transfer of gasses from the foamed polyesterlayer 2128 and through perforations 2136.

Rib Forming Apparatus

Referring now to FIG. 258, a cross-section through a tooling assembly oftool parts 2200 and 2202, with a section of material 2124 (afterprocessing/forming), is shown. Tooling part 2200 is temperaturecontrolled by passing liquid 2206 through conveniently locatedpassageways shown as ports 2204. Liquid is preconditioned to a specifiedand desired temperature and is passed through ports 2204 at a ratesufficient to control the temperature of tooling part 2200. Similarlypart 2002 can be temperature controlled in a similar manner (not shown).Evacuation holes 2208 are located in part 2200 and evacuation ports 2210are also located in tooling part 2202. A plan view of cavity 2212 isshown in FIG. 259 with length and width dimensions respectively alsoshown. FIG. 260 shows a cross-section through a section of material,which has been sealed around its periphery 2124 by compressing andsealing the outer layers together, before processing with matching toolparts 2200 and 2202. Tooling assembly includes two parts 2200 and 2202and the face 2214 of part 2200 is arranged to have width and lengthdimensions such that it can enter and partially penetrate cavity 2212with a clearance around the perimeter of the cavity of 0.010″, such thatthe parts 2200 and 2202 are in close proximity but substantially do notcontact each other. The tooling parts 2200 and 2202 can be mounted ontoindependently moving members that can simultaneously provide apredetermined closing movement toward each other and with a desiredforce. Face 2214 is parallel to face 2216 and when parts 2200 and 2202are closed together in a closed position, parts 2200 and 2202 arearranged so as not to contact and the distance between face 2214 on part2200 and 2216 on part 2202 is at a set predetermined distance. Avertical wall 2218 is located around cavity 2212 and when part 2200 and2202 are in a closed position an enclosed space is so defined by face2214, face 2216 and walls 2218. Therefore, the volume of space can bepredetermined and the displacement of section of material 2124 can alsobe predetermined. Volume and displacement can be arranged to besubstantially equal. A section of material 2124, shown in FIG. 260 isheated to a desired temperature and located into the cavity 2212immediately prior to closing parts 2200 and 2202, such that when parts2200 and 2202 are closed and a vacuum source is applied to evacuationports 2210 and passageways 2208 in parts 2200 and 2202, the profile ofthe section of material 2124 will be altered, so as to substantiallyconform to the profile of the space wherein ribs 2220 will be formed byrib mold 2222 in face 2214. This method of forming a part with a desiredprofile from a substantially flat (two dimensional) sheet of material2124 can be applied to form parts such as trays. The profile of thetrays will be determined by the profile of the tooling parts which canbe manufactured to specific requirements and particularly to provide amethod of producing trays of optimized profile and rigidity for use, forexample, in master container modified atmosphere packaging system asdescribed herein.

Removal of Oxygen from Cell Structures

Referring now to FIG. 261, a cross-sectional view of a pressure chamberapparatus, vacuum tube 4900, is shown. The apparatus is intended to beused in the process of removing any oxygen gas that may be retainedwithin the cell structure of expanded polystyrene foam packagingmaterials such as trays with flaps, that are intended for use inpackaging perishable products such as red meats in a low residual oxygenmodified atmosphere package. The vacuum tube 4900 includes a tube ofsuitable length, open at both ends with end caps 4904 and 4906 fitted toeach end which together, provide a sealed and air tight pressurechamber. The end caps can be clamped in position and are removable asdesired. The vacuum tube 4900 may be manufactured from any suitablematerial such as aluminum, stainless steel or a plastic material or acombination thereof. The size and profile of the vacuum tube can bearranged to suit and accommodate a magazine, such as is detailed in FIG.263. The magazine has an outer profile and dimensions such that it canbe readily located inside the vacuum tube 4900. The inner profile of themagazine 4908 is arranged to suit a particular size of tray with flaps.A plurality of a particular size of tray with flaps can be locatedwithin the magazine and held in this position as required for furtherprocessing as a complete unit. A plurality of magazines can be providedto suit any desired sizes of trays with flaps. A piston 4910 fitted withseals between the piston and the internal surface of bore of the vacuumtube 4900 can be located in the bore of the vacuum tube adjacent to endcap 4906. The piston can be manufactured from materials that include asuitable quantity of a magnetic material such as iron. The piston isarranged so as to move easily within the confines of the vacuum tubealong the bore. The end cap 4906 can be manufactured with anelectromagnetic devices attached thereto that are capable of activationas required in a manner that, as and when required, will cause thepiston to become magnetically attached thereto. A port 4912 is providedin the end cap 4906. Two manifolds marked manifold 4914 and manifold4916 are fitted on opposite sides of the vacuum tube 4900. The manifold4914 has direct communication with the vacuum tube through apertures4918 and manifold 4916 has direct communication with the vacuum tubethrough apertures 4920. Ports are provided at each end of the manifolds.The manifold ports 4922, 4924, 4926 and 4928 are connected to a vacuumsource and nitrogen gas or any other suitable gas source, via athree-way valve such that either gas, set at a selected and adjustablepressure, or alternatively a vacuum source can be attached directly tothe manifold ports. The gas supply and the vacuum source can bealternately attached to each manifold port, together or separately, inany desired sequence and/or manner that will efficiently remove residualoxygen from cell structure of packaging materials contained in thevacuum tube 4900.

A plurality of vacuum tubes 4900 may be manufactured in suitablequantities and arranged so as to be attached to an apparatus such asshown in FIG. 267. The vacuum tubes 4900 are arranged to allow thetransfer of magazines 4908, therethrough after removal of both end capswith the piston electro-magnetically attached to end cap 4906.Alternatively the trays with flaps may be transferred from the magazine4908 directly there from. Empty magazines can then be returned byautomatic transfer to a known location and as controlled by aprogrammable CPU or PLC (programmable logic controller) attached to themagazine assembly.

Referring again to FIG. 267, an apparatus is shown as vacuum tubeassembly, and includes a quantity of preferably 23, horizontally andparallel disposed vacuum tubes, similar to 4900, and each markedindividually can be seen attached to a pair of parallel and continuouschains that are in turn arranged to engage with sprockets that are inturn arranged with suitable drivers. The quantity of vacuum tubes,attached to the chains, may be varied according to requirements.

An apparatus shown as magazine assembly, including a quantity ofpreferably 23, to correspond to the number of vacuum tubes horizontallyand parallel disposed magazines, with each magazine similar to magazine4908, and each marked individually, secured to a pair of parallel andcontinuous chains, that are in turn arranged to engage with sprocketsthat are in turn arranged with suitable drivers. The magazines arearranged so as to be detachable from the magazine assembly.

The vacuum tube assembly and the magazine assembly are arranged suchthat magazines can be automatically transferred between the assemblies,as required. In this way a magazine that has been loaded with trays withflaps can be selectively transferred from the magazine assembly to aselected vacuum tube location in the vacuum tube assembly

A quantity of preferably 4 thermoforming machines 4948, 4950, 4952 and4954 are shown positioned adjacent to the magazine assembly so as trayswith flaps, produced by the thermoforming machines, can be loadeddirectly into the magazines. Any suitable quantity of thermoformingmachines with interchangeable tooling to suit any number of differentsizes of trays with flaps can be provided, as required, and locatedadjacent to the magazine assembly.

Machines 4948, 4950, 4952 and 4954 include suitable thermoformingmachines that are arranged to thermoform trays with flaps from suitablerolls of expanded polystyrene sheet provided on rolls 4956 on spools4958. Each thermoforming machine includes ovens and forming and trimming(cutting) devices. Trays with flaps are thermoformed, trimmed andejected in horizontally disposed stacks, such that the stacks extendonto shelves 4960 and 4962 arranged on each machine 4948 through 4954.Magazines 4900 can be positioned adjacent to and in line with stacks onshelves 4960 and 4962 so as to facilitate loading of the trays withflaps directly therein. Preferably, trays with flaps can be produced bythermoforming machines 4948, 4950, 4952 and 4954 and loaded directlyinto any selected magazine. Each magazine has an address which is knownand a computer a CPU (central processing unit) can control thethermoforming machines in concert with the magazine assembly. Anysuitable quantity of thermoforming machines can be arranged at positionsadjacent to the magazine assembly. Each thermoforming machine can bearranged to produce different sizes of trays with flaps, as required,which can be arranged to be transferred and loaded into suitablemagazines with known addresses.

Preferably, magazine assembly and the vacuum tube assembly can bearranged to operate in concert and controlled by the CPU.

Apparatus that is arranged to fold and bond trays with flaps are shownand marked 4964, 4966, 4968, 4970 and 4972 and arranged to fold and bondtrays with flaps of different sizes, and specification details, asrequired. The CPU is programmed with the location of each machine 4964,4966, 4968, 4970 and 4972 and specification details of trays with flaps.Accordingly, the apparatus can be programmed to operate in concert withthe vacuum tube assembly such that magazines can be transferred betweenthe apparatus and the magazine assembly by transfer of magazines tomagazine locations shown as magazine 4974, 4976, 4978, 4980, 4982 asrequired for subsequent folding and bonding. After folding and bondinghas been completed by any of the machines 4964, 4966, 4968, 4970 and4972, finished trays are positioned onto the respective conveyors 4984,4986, 4988, 4990 or 4992 for transport thereon to packaging machines.

The magazine assembly and/or the vacuum tube assembly can be enclosed ina space that can have a suitable gas, such as nitrogen, provided thereinand temperature controlled at a suitable temperature.

Apparatus shown in FIG. 267 is thus arranged to automatically producetrays with flaps on the thermoforming machines. The trays with flaps canthen be transferred into magazines that can be secured to the magazineassembly. The magazines can be transferred from the magazine assembly toany of the vacuum tubes attached to the vacuum tube assembly. Trays withflaps can then be processed according to any suitable process and asherein disclosed. The magazines can then be transferred to the foldingand bonding apparatus for further processing and subsequent transfer topackaging machines for use in packaging perishable goods.

The tray with flaps, folding and bonding machines 4964, 4966, 4968, 4970and 4972, are arranged to fold and bond any trays with flaps ofdifferent specification details. The CPU is programmed with location ofeach machine 4964, 4966, 4968, 4970 and 4972, and specification detailsof trays with flaps stored in the magazines. Accordingly, the vacuumtube assembly can be programmed to unload trays with flaps intomagazines 4974, 4976, 4978, 4980 and 4982, as required for subsequentfolding and bonding. After folding and bonding has been completed by anyof the machines 4964, 4966, 4968, 4970 and 4972, finished trays arepositioned onto the respective conveyors 4984, 4986, 4988, 4990 or 4992for transport thereon to packaging machines.

The thermoforming machines 4948, 4950, 4952 and 4954 and the tray withflaps, folding and bonding machines 4964, 4966, 4968, 4970 and 4972, thecorresponding magazines 4974, 4976, 4978, 4980 and 4982 and conveyors4984, 4986, 4988, 4990 or 4992 can be enclosed in a space that can havea suitable gas, such as nitrogen, provided therein.

The nitrogen gas can be produced by a suitably sized nitrogen generatorsuch as an on-site nitrogen supply, incorporating a non-cryogenic airseparation apparatus known as Pressure Swing Absorption (PSA)Generators. Suitable PSA generators are available from BOC Gases, adivision of The BOC Group. Any convenient source of gas supply may beused.

Apparatus for the Removal of Oxygen from Cell Structures

Referring now to FIGS. 262-265, an apparatus that is intended to be usedin the process of removal of any oxygen gas that may be retained withinthe cell structure of expanded polystyrene foam trays and flaps that areintended for use in packaging perishable products such as red meats in alow residual oxygen modified atmosphere package is shown. FIG. 262 showsdetails of three identical vacuum tubes 4800 in various stages of theprocess and at positions A, B and C. Each vacuum tube includes a tube,open at one end and closed at the other. The vacuum tubes may bemanufactured from any suitable material such as aluminum, stainlesssteel or a plastic material or a combination thereof. The size andprofile of the vacuum tubes can be arranged to suit and accommodate anysizes of the tray with flaps. A piston 4802 fitted with a seal betweenthe piston and the internal surface of bore of the vacuum tube, such as“O” rings appropriately attached to the piston, can be located in thebore of each vacuum tube. The piston is arranged so as to move easilywithin the confines of the vacuum tube along the bore, with low frictionand resistance between the bore and the piston “O” rings. A port 4808 isprovided in the closed end of each vacuum tube and a cap 4810 isprovided, when required, to completely close and seal in an airtightmanner, the open end of the vacuum tubes. Two manifolds marked 4812 and4814 are fitted on opposite sides of the vacuum tubes. The manifold 4812has direct communication into the vacuum tube through apertures 4816 andmanifold 4814 has direct communication with the vacuum tube throughapertures 4818. Ports are provided at each end of the manifolds. Themanifold ports 4820, 4822, 4824 and 4826 are connected to a vacuumsource and nitrogen gas or other suitable gas source, via a three-wayvalve such that either gas, set at a selected and adjustable pressure,or alternatively vacuum source can be attached directly to manifoldports. The gas supply and the vacuum source can be alternately appliedto each manifold port in a manner that will most efficiently remove theresidual oxygen from the cell structure.

Referring now to FIG. 264, a rear end elevation of the apparatus isshown. As can be seen, four horizontally disposed vacuum tubes 4800, aremounted to a frame 4830 which is in turn attached to a main frame 4830via pivot 4832. The main frame 4830 is rigidly attached to base of framethat is located fly on a floor. A driver 4832 is provided and arrangedto rotate the vacuum tubes about pivot 4832. The drive can rotate thevacuum tubes, attached to frame 4828, all together as a single unit,with an intermittent motion such that during each intermittent motionthe frame 4828 with vacuum tubes 4800, moves through 90 degrees or aquarter a single revolution. In this way vacuum tube 4800 at position Awould move to the position B. The vacuum tube at position B would moveto D and D to A. The apparatus is arranged so as to allow automaticloading of a quantity of trays 4834 at position A. At position B, thevacuum tube is arranged to be sealed with trays 4834 therein andposition 5100 is arranged so as to allow unloading of the trays 4834from vacuum tube 4800.

Referring again to FIG. 262, with vacuum tube 4800 at position A, trays4834 are shown being loaded into the vacuum tube with a loading force.During the loading, a suitable gas such as nitrogen can be providedthrough port 4808 of the vacuum tube at position A, at a desiredpressure so as to exert a desired level of force against piston 4802,thereby holding the trays 4834 in a firmly held, nested, dispositionwhile submitting to the loading force. The piston thereby moves towardthe closed end of the loading vacuum tube until the vacuum tube isfilled with trays. Cap 4818 is then positioned into the open end of thevacuum tube thereby sealing in an airtight manner with trays 4834enclosed therein. Immediately after closing and sealing the open endwith cap 4810, a vacuum source is attached to all ports 4820, 4822,4824, and 4826. The vacuum source remains attached thereto for a setperiod of time, sufficient to remove substantially all air from theclosed vacuum tube 4800. After evacuation of substantially all air fromthe vacuum tube 4800 at position A, the vacuum source can bedisconnected from manifold 4812 and a nitrogen gas source attachedthereto, such that nitrogen gas is provided into manifold 4812 andthrough apertures 4816 so as to flood the vacuum tube at a desiredpressure. The nitrogen gas then flows across the surfaces of trays 4834and through apertures 4818 and into manifold 4814. The vacuum source canthen be disconnected from the manifold 4814 so as to allow pressure ofnitrogen gas inside vacuum tube to be increased to a desired pressure.The nitrogen gas can be maintained at the desired pressure for a desiredperiod of time sufficient to allow exchange with and thereby removal ofsubstantially all oxygen that may be present in the cell structure ofthe trays with flaps. Alternating and or pulsating vacuum and gassing ofthe vacuum tubes can be arranged so as to provide rapid removal of theoxygen gas. A gas analyzer can be attached to each vacuum tube andarranged to determine the residual oxygen gas content inside the vacuumtube. When the residual oxygen content of gas present inside the vacuumtube has been reduced to a desirable level, the frame 4828 with vacuumtubes 4800 attached, can be then rotated so that the vacuum tube atposition B is rotated to position 5100, the cap 4810 is removed and thetrays 4834 are extracted by providing nitrogen gas through port 4808 ata suitable pressure so as to cause the piston to move toward the openend of the vacuum tube and eject the trays through the open end of thevacuum tube. Suction cups 4836 may be used to intermittently remove asingle tray at a time until the vacuum tube is emptied.

Each vacuum tube 4800 can be provided with individual and separateidentification. Preferably, separate identification may be arranged byway of a bar code attached to the vacuum tube, at a convenient locationor alternatively it may be by way of a chip, embedded into a section ofeach vacuum tube.

The vacuum tubes 4800 may be arranged to accommodate any size of traywith flaps. The trays with flaps may be pre-loaded into an open magazine4838, such as shown in FIG. 263, that is arranged to fit inside any ofthe vacuum tubes 4800. Any suitable quantity of open magazines may beprovided and each one can be arranged so as to have constant outerdimensions that allow close and neat fitting within the vacuum tubes4800, while the open magazine internal dimensions are arranged to suitdifferent sizes of trays with flaps. Each magazine can be fitted with anindividual address or identifying mark such as a machine readable andrecognizable bar code or computer chip, embedded into the magazine atany convenient location. The address of the individual open magazine canthereby be identified. The open magazine can be loaded with the trayswith flaps and then stored in, for example, a suitable racking systemfor a period of time, and when required for use, the loaded openmagazine can be automatically removed from the racking system andtransferred to the vacuum tube 4800 for processing. Any convenientquantity of open magazines can be manufactured and loaded with trays ofvarious sizes, collectively providing an open magazine. The rackingsystem may be located inside an enclosed storage space that may befilled with a desired gas such as nitrogen. In this way the procedure ofloading, processing and then unloading the trays with flaps, in thevacuum tubes 4800, that have been stored in the open magazine withidentifiable address, may be arranged in an automatic process. Trays canbe held within the magazine by a clip or a brush.

The vacuum tubes 4800 may be attached to any suitable mechanism with thecapability of positioning the vacuum tubes as required, such as is shownin FIG. 262.

Referring now to FIG. 266, a plan view of various apparatus constructedaccording to the present invention is shown. A pair of horizontallydisposed, parallel, continuous chains 4846 are arranged on suitablesprockets 4848 mounted in a frame. The sprockets are attached to adriver (not shown) that includes a programmable servo motor arranged todrive the parallel chains, in either direction, as required. Vacuumtubes 4800 are fixed to continuous chains 4846 as shown and includes aquantity of preferably 23 vacuum tubes, marked with individual addressesto provide a vacuum tube assembly generally denoted by 4850. The vacuumtubes are positioned with the closed ends toward the rear of equipmentlayout and the open ends toward the front of the equipment layout.

Thermoforming machines 4852 and 4854 are positioned adjacent to thevacuum tube assembly so as trays produced therewith can be loadeddirectly into vacuum tubes. Three tray with flap, folding and bondingmachines 4856, 4858 and 4860 are located adjacent to the vacuum tubeassembly.

Machines 4852 and 4854 include suitable thermoforming machines that arearranged to thermoform trays with flaps from suitable rolls of expandedpolystyrene sheet provided on rolls on spools 4864. Each thermoformingmachine includes ovens forming and trimming apparatus. Trays with flapsare thermoformed, trimmed and ejected in horizontally disposed, andnested quantities onto shelf 4866 and 4868. Vacuum tubes 4870 and 4872are positioned adjacent to and in line with shelf 4866 and 4868 so as tofacilitate loading of the trays with flaps directly therein. In thisway, trays with flaps can be produced by thermoforming machines 4852 and4854 and loaded directly into the vacuum tubes. Each vacuum tube has anaddress which is known, and a computer, with CPU (central processingunit) can control the thermoforming machines in concert with the vacuumtube assembly. Any suitable quantity of thermoforming machines can bearranged at positions adjacent to the vacuum tube assembly. Eachthermoforming machine can be arranged to produce different sizes oftrays with flaps, as required, which can be arranged to be transferredand loaded into vacuum tubes with known addresses. Alternatively, thethermoforming machines may be arranged so as to produce trays with flapsfor loading into open magazines for subsequent storage before processingon the vacuum tube assembly.

The tray with flaps, folding and bonding machines 4856, 4858 and 4860are arranged to fold and bond the trays with flaps of differentspecification details. The CPU is programmed with location of eachmachine 4856, 4858 and 4860 and specification details of trays withflaps. Accordingly, the vacuum tube assembly can be programmed to unloadtrays with flaps into magazines 4874, 4876 and 4878, as required forsubsequent folding and bonding. After folding and bonding has beencompleted by any of the machines 4856, 4858, and 4860, finished traysare positioned onto the respective conveyors 4878, 4880 or 4882 fortransport thereon to packaging machines.

The tray with flaps, folding and bonding machines 4856, 4858, and 4860,the corresponding magazines 4878, 4880 or 4882 and conveyors can beenclosed in a space that can have a desirable gas, such as nitrogen,provided therein.

The desirable gas, such as nitrogen can be produced by a suitably sizednitrogen generator such as an on-site nitrogen supply, incorporating anon-cryogenic air separation devices known as Pressure Swing Absorption(PSA) Generators. Suitable PSA generators are available from BOC Gases,a division of The BOC Group. Any convenient source of gas supply may beused.

FIG. 105 shows a cross section through an apparatus that may be used forpumping pre-blended grinds into a profiled conduit thereby providing anextruded stream of grinds for subsequent slicing and production ofpatties. An enclosed housing 12 is shown with a tapering screw 15mounted therein. The external surfaces of the tapering screw can beprofiled to match the internal surface of housing 12 such that thesesurfaces are in close but not touching proximity and so that the screw15 will scrape the internal surface of the housing 12. The arrangementin FIG. 105 shows a single screw but may alternatively be arranged withparallel sides that are not tapered. The screw is most preferablytapered and may be mounted in tandem and adjacent to a counter rotating,correspondingly matching, second tapering screw (not shown) in paralleltherewith. Such a pair of matched and meshing screws can provide a meansto scrape all surfaces of the screws and all internal surfaces ofhousing 12. As shown in FIG. 105, screw 15 is driven via a shaft 14attached to a suitable driving motor (not shown) such as a servoelectric motor, which can drive the screw(s) in a direction indicated byarrow 14 and at a variable speed. Pre-blended grinds 20 that have beenprocessed as required in enclosed vessels (not shown) that substantiallyexcluded oxygen from contact thereto, are provided by any suitabletransferring mechanism into conduit 9 which is attached via a gas tightflange 11 to housing 12. Grinds 20 provided into housing 12 aresubstantially free of air or oxygen and any voids contained therein canbe substantially filled with carbon dioxide. Grinds 20 can betransferred into housing 12 at a controlled temperature below thefreezing point of water such as at 29.5 degrees F. Housing 12 may befitted with a suitable jacket and insulation with conduits providedtherein (not shown) through which any suitable liquid, maintained at anysuitable temperature, can be transferred. A piston 16 is shown locatedwithin a cylinder 25, which in turn, is mounted directly to housing 12.Piston 16 can be directly coupled to a driving mechanism (not shown)that will activate movement of the piston in a reciprocating manner withdirections of movement shown by double headed arrow 27. FIG. 107 showspiston 16, cylinder 25, grinds 20, and screw 15 and it can be seen thatthe end of piston 16 is provided with a radius 26, that matches theexternal radius of screw 15 such that when piston 16 is in close but nottouching proximity to rotating screw 15, the external surface of piston16 at 26 will be wiped by the outermost edges of screw 15 as it rotates.In this way substantially no fat or grinds can accumulate by sticking tothe exposed surface of piston 16, at 26. A single matching piston andcylinder assembly is shown mounted to housing 12, however, more than onesuch matching assembly may be mounted in radial disposition to housing12. In fact, for example, three or four such matching piston andcylinder assemblies may be mounted around the circumference of housing12 and arranged to operated simultaneously or as may otherwise berequired. Mounted to the exit end of housing 12, a conduit 18 is fixedin a sealed and gas tight manner. Conduit 18 is shown with a restrictiontherein, such that the internal diameter at the point of entry isidentical to the internal diameter of housing 12 and the diameter ofconduit 18 is tapered so as to reduce the cross sectional area andtherefore, when grinds are pumped there through, back pressure isgenerated against the exposed end surface 26 of piston 16. A flange 19is shown at the exit end of apparatus shown in FIG. 105 which maycorrespond with matching flanges of profiled conduits (such as 45 inFIG. 106) that can be interchangeably attached thereto, to provide adifferent profiles and size of extruded streams of grinds pumped therethrough. An arrow 29 shows the direction of flow of extruded stream ofgrinds 20.

In a preferred embodiment, grinds 20 are transferred into housing 12 andcarried in a forward direction, indicated by arrow 29, by rotation oftapered screw 15, in a continuous stream. During transfer throughhousing 12, grinds 20 are compressed so as to ensure any voids that maybe contained therein are eliminated by dissolving of CO2, contained inthe voids, into said grinds. As stream 20 is transferred in thedirection shown by arrow 29, a cone shaped conduit at 18 furtherrestricts stream of grinds 20 and compresses it into a substantiallyvoid free stream exerting a back pressure that is proportionate to thevelocity of stream 20 and the restriction according to the diameter ofconduit 18. Alternatively, other suitable restrictive conduits or valvesmay be provided in place of conduit 18. In order to provide a stream ofgrinds that has been conditioned to a suitable temperature, housing 12can be temperature controlled by any suitable heat exchanging andtemperature controlling apparatus.

In a preferred embodiment, a mechanism is provided for slicing beefpatties from a continuous stream of grinds, allowing slicing ofindividual patties to occur while the stream of grinds is stationaryrelative to the knife. This can be achieved by moving the slicingmechanism parallel with and at the same speed as the stream of grindsand slicing while in motion followed by rapid return of the slicingmechanism to an original position in readiness for subsequent slicing.However, this can be difficult to control and high production output isgenerally not possible. In a preferred embodiment the stream of grinds20 is halted at the time of slicing. Most preferably the velocity ofstream 20, at the exit point 30 can be adjusted between a maximum rateof flow that is substantially determined by the speed of rotation ofscrew 15, and zero velocity by controlled activation of piston 16. Thismay be achieved by activating piston 16, so that it moves, at acontrolled rate, away from the housing 12 and therefore increasing theavailable volume within cylinder 25 that can be filled with grindstransferred by screw 15 and momentarily at a rate equal to the transferof grinds through housing 12. This arrangement can provide a momentaryreduction of flow and halting of stream of grinds 20 at exit point 30.In order to achieve this, and ensure that there is no movement of saidstream of grinds at exit point 18, the rate of increase in availablevolume in cylinder 25 must be equal to the volumetric rate of flow ofstream of grinds 20. Therefore, by activating piston 16 in areciprocating manner, grinds can be intermittently accommodated withinspace 31, in cylinder 25 and then immediately expelled therefrom in acontinuously repeated cycle. In this way, velocity of stream of grinds20, can be intermittently varied between a maximum rate of flow andsubstantially no rate of flow, by adjusting the flow rate provided byrotation of screw 15 in concert with the cyclical reciprocating motionof piston 16. Furthermore, additional piston and cylinder assemblies maybe installed to provide larger capacities of volumetric variation inspace 31 and to vary the quantity of grinds extruded during each flowcycle from the exit end of conduit 18 at 30. Any quantity of grindsextruded during each piston 16 cycle can be arranged to be equal to thedesired weight of a single beef pattie. This cycle rate may be arrangedto exceed 500 cycles per minute and, for example, if it is desired toproduce quarter pound beef patties, at this rate of 500 cpm, a totalrate of production would be equal to 125 lbs. of patties per minute.

Referring now to FIG. 106, a cross section through an apparatus intendedfor use in slicing extruded streams of ground meats, as described abovein FIG. 105 to produce patties, is shown. Any suitable cutting blade maybe used to slice from a continuously extruded section 40, such as ahigh-speed, band blade that is driven by a suitable electric motor.Referring now to FIG. 105 and FIG. 106, a temperature controlledconduit, 45, with flange 41, is arranged so that it can be mounteddirectly to the flanges 19, of apparatus shown in FIG. 105. An arrow 42shows the direction of flow of a stream of grinds 40 transferred fromconduit 18, via orifice 30 into conduit 45. Conduit 45 may be providedat any suitable length 43, and can be arranged with temperaturecontrolling conduits 44 imbedded in the walls of conduit 45. Anysuitable liquid that will remain liquid at a selected temperature may betransferred through conduits 44 at a flow rate that will ensuretemperature control of stream 40 as may be required. A knife cuttingblade 47 with suitably machined bearing attachment 54 is shown mountedto a driving shaft 46. Conduit 45 is mounted at a convenient angle andadjacent to revolving blade 47 such that as blade 47 is rotated, pattiescan be sliced from stream of grinds 40 and deposited into stacks ofsliced patties as shown at 51 and 52. In this way, patties can beproduced, stacked and transported to a packaging station via conveyorbelting 50 that is driven intermittently by a drive roller 49 in adirection shown by arrow 52.

In order to minimize accumulation of fat and/or ice on the internalsurfaces of conduit 18, scrapers (not shown) may be mounted, for exampleto the end of screw 15 to scrape internal surfaces thereof.Additionally, internal conduit surfaces may be treated with non-sticksurfaces that are resistant to any such build up of fat and/or ice.Furthermore, separate temperature zones may be arranged such that, forexample, housing 12 may be maintained at 29.5 degrees F. and anysuitable insulation provided at the connection between conduits 18 and45. In this way conduit 45 may be set at a much lower temperature suchas 10 degrees F. so as to cause a “crust” freezing of the externalsurface of stream of grinds 40 and thus provide an improved conditionfor slicing by knife 47. The intermittently varied velocity of stream ofgrinds 18 can be directly and correspondingly integrated with eachrevolution of knife 47 such that during the knife cutting action ofstream 40, the velocity of stream 40 is reduced to virtually zero andthen as the knife rotates through an arc away from the stream 40 andtoward the next slicing of the subsequent pattie, the velocity of stream40 can be accelerated then decelerated so as to be again in asubstantially stationary position for subsequent slicing by said knife47. Control of stream 40 flow rate is therefore provided by thereciprocating action of piston 16.

Referring now to FIG. 108, a side elevation of an apparatus assembled tocontinuously produce fine ground boneless beef 77, from coarse groundboneless beef 61 in an enclosed system that substantially excludesoxygen, is shown. Coarse ground beef 61 is transferred through conduit63 to fine grinder 65. Flanges 62 and 64 are fixed together to provide agas and liquid tight seal there between allowing continuous transfer ofpressurized coarse ground beef 61 to fine grinder 65. Ground beef 61 and77 can be maintained at a selected temperature such as 29.5 degrees F.Fine ground beef 77 is then transferred into vessel 70 from grinder 65,and allowed to accumulate therein. A connection to vessel 70 from a gassource, via a pipe 78 provides a conduit to deliver suitably pressurizedgas such as carbon dioxide into vessel 70 and to allow contact ofselected gas with grinds 77. Also, a conduit 79 allows controlledrelease of excess gas that may accumulate in vessel 77, for example viacontrolled pressure release valves (not shown) installed in conduit 79.In this way a selected gas such as carbon dioxide can be provided in anyfree space in vessel 70, at a constant, selected gas pressure. Positivedisplacement pump 71, is driven via shaft 72, that in turn is driven bya servo electric motor (not shown) or other such suitable variable drivemotor and in such a manner as to allow adjustment, as required, to therate of pumping of fine grinds 77 from vessel 70 into conduit 73. Pump71, may also provide a controlled pressure inducing feature by itspumping action of fine ground beef 77 into conduit 73 thereby causingsubstantially all gaseous voids, contained in 77, to be eliminated bydissolving of any free CO₂ gas contained therein. In this way, grinds 77that may contain voids or spaces filled with CO₂ can be transferred to asolid stream of grinds 20 that is substantially free of any voids. Solidstream of grinds 20 may be transferred in the direction shown by arrow74 to directly connect to conduit 9 shown in FIG. 105.

The aforementioned method and apparatus for the processing meats refersnot exclusively but most preferably to ground meats that are can bepumped via a single or several positive displacement pumps. In manyother applications, production of meat food products, that involveslicing of large pieces of beef, is required. It has been determined, bythe present inventor, that preventing contact of the freshly cut beefsurface with atmospheric air can provide enhancement of storage life.Consumers, in general will only buy red meat and therefore toaccommodate the needs of the consumer and the requirements of the meatpacker, the present invention is directed at providing an improvedprocess whereby meat is sliced by automatic apparatus, directly into anenclosure that excludes air (and oxygen). Therefore, in anotherpreferred embodiment, apparatus shown in FIG. 109 and the followingdisclosure, an apparatus that can slice primal beef portions directlyinto an enclosure with an oxygen free gas therein, is detailed.

Referring now to FIG. 109, a round cross sectional conduit 81 ishorizontally disposed and mounted with an exit end 103 directly adjacentand above an end of a conveyor 94, that is mounted at an elevating angleto the horizontal. The conveyor elevating angle is set such that slicesof meat will be urged forward by the action of blade 92 as it rotatesand descends, slicing through the primal so that the sliced andseparated portion will fall gently onto the conveyor 94. Enclosure 98can be filled with carbon dioxide gas 99 or other suitable gas that isheld at a suitable temperature and gas pressure above ambientatmospheric pressure and in such a manner to ensure that substantiallyno air and most importantly, no atmospheric oxygen can enter enclosure98. The profile of conduit 81 may be chosen to suit any particularproduct which may not be round and for example, a square or rectangularprofile may be chosen, however, in this instance a round profile hasbeen shown. A blade 92 attached to a shaft 91 is conveniently mounted atthe exit end 103 of conduit 81 such that slices 94 can be cut from theend of primal 87 after emerging from conduit 81. Blade 92 can bearranged to cut a single slice during a single revolution of shaft 91.Therefore the intermittent sequencing of firstly driving blade 92 for asingle revolution to cut a single slice, followed by the measured andcontrolled movement of a primal such as 87 from the exit end 103 ofconduit 81 can be arranged to automatically and continuously operate.Slices 94 can then be carried forward in a continuous or intermittentand controlled action for further processing or packaging, alongconveyor 94 driven in the direction shown by arrow 96, by roller 93.

Plugs 82, 85 and 89 are shown in cross section and located on the insideof conduit 81 between primal beef portions 87. Primal beef portions 87may have been previously processed and allowed to set in a mold, afterpre-rigor mortis harvesting from a slaughtered animal, such that thecross sectional dimensions of the molded primal correspondssubstantially with the cross section of conduit 81. This method ofmolding primal cuts of meat has previously been described in theinventor's earlier patent disclosures and while the primal cuts can varyin size, molds can be arranged such that only those dimensions shown bynumbers 101 and 102 will significantly vary. In this way, primal cuts ofmeat may be located into the entry end of conduit 81 and in thedirection shown by arrow 100. After locating a primal 87, into the entryend of conduit 81 a plug such as 82 is then loaded directly behind theprimal 97 followed by another primal and then another plug such that acontinuous sequence of primal cuts, each with a plug interposed between.Each plug such as 82 comprises a profiled “piston” with an iron core 88enclosed in a plastics frame 85. Each iron core 88 may be magnetized tosuch an extent that, when a suitably mounted electromagnet is adjacentthereto a magnetic bond is developed between the iron core 88 and theelectromagnet that is substantially unbreakable by any force that islikely to be applied to either part in this apparatus application. Frame85 is arranged with one or more flexible lips 86 that can sealinglycontact the inner surface of conduit 81 and but allow plugs 82 to slidealong the internal surfaces of conduit 81, flexible lips 86 can therebyprovide a seal around the full perimeter of plug 82 with conduit 81 andcan therefore act as a piston held captive within the conduit 81. Aseries of electromagnetic rings 83, are mounted to a drive mechanism(not shown) and each electromagnet is “mated” with a single plug such as82, located on the inside of conduit 81. The distance between each plugsuch as 82, and as shown in examples 101 and 102 can be electronicallymeasured by proximity devices conveniently mounted external to theconduit 81 and adjacent thereto and in such a manner so as to allowmeasurement of any distance between any two plugs. In this way, anyparticular primal cut of beef can be measured and with suitable computerapparatus arranged and connected to any suitable measuring arrangementsuch as said proximity switches, a selected quantity of slices can beautomatically calculated and subsequently sliced as the primal emergesfrom the exit end of conduit 81 by knife blade 92. It may be preferableto remove a thin section of sliced meat from each end of each primal anddivide the balance into a quantity of slices having a desirablethickness. Alternatively the length of each primal, as shown in examples101 and 102, can be divided into a selected number of slices with athickness automatically calculated, accordingly. Alternatively, slicesof a chosen weight may be calculated by computer apparatus. In allcases, the primal cuts can be automatically and intermittentlytransferred along conduit 81 with each forward movement ofelectromagnets 83 which carry plugs such as 82 forward simultaneously.In this way, the thickness of any slice cut by knife 92 can bedetermined by the distance of each forward movement of electromagnets83. As plugs, such as 82, are carried forward and emerge from exit end103, the operation of blade 92 can be arranged to allow the automaticremoval of each plug and subsequent transfer to the entry or loading endof conduit 81 in readiness for its next use. Plugs can be sanitizedprior to next use as may be required.

Conduit 81 can be temperature controlled by any suitable method whichmay be provided by circulating liquid, such as glycol, through conduitsprovided within or in contact with the walls of conduit 8, and theinternal surface of conduit 81 may be treated so as to resist “sticking”to anything passed there through. In this way, primal portions of beefmay be “crust frozen” during transfer through conduit 81. One or moreconduits, such as 97, may be provided to connect a vacuum, gas orselected agent source directly to conduit 81.

Perishable food products produced, in part or otherwise, in the mannerdescribed herein may be placed in any suitable tray with or without anysuitable substance and over wrapped with any suitable web of materialsuch as pPVC and then placed in a master container that may bemanufactured from a substantially gas barrier material or partial gasbarrier material to provide finished packages. Following this, finishedpackages may be stored in any suitable storage room maintained at anysuitable temperature until required for sale, at which time finished maybe removed, labeled and displayed for sale in a retail outlet such as asupermarket.

Electronic Method of Transacting Business

Referring now to FIG. 275, a schematic representation of an apparatusfor storing and processing goods in a meat processing train resident ina meat processing plant, is illustrated.

A pressure vessel 8058 is connected directly to a supply conduit 8002 ina gas and liquid tight manner, such that goods 8012 can be transferredthrough conduit 8002 and into vessel 8058 for storage and processingtherein. Vessel 8058 may be arranged in an inclined disposition so as toreduce the depth of goods, measured along a vertical, straight lineinside the vessel, contained therein. Vessel 8058 may also be arrangedwith a suitable blending arrangement mounted therein in such a manner soas to allow blending of any goods stored in or transferred throughvessel 8058. A fat, protein and water content measuring device 8004 isinserted between conduit 8002 and valve 8006. The measuring device 8004may be mounted at the connecting point and directly between conduit 8002and vessel 8058 to provide a means of isolating conduit 8002 from vessel8058 in a gas tight manner. A tube 8060 connects vessel 8058 to a sourceof suitable gas or agent via a suitable valve (not shown) to allowtransfer of any suitable gas or agent, such as any storage lifeenhancing gas, into vessel 8058. A port 8008 with connection hose to asuitable vacuum generator is provided in the wall of vessel 8058 at anupper location so as to allow evacuation of gases from vessel ifrequired. A connection to conduit 8016 is provided at a lower locationin the vessel 8058 such that any goods transferred into vessel 8058 willtend to gravitate there toward, irrespective of any mechanicaltransferring arrangement that may be mounted inside vessel 8058. Conduit8016 is connected directly to a positive displacement pump 8022 via aliquid collection point arranged to collect any purge 8018 or liquidsthat may accumulate in vessel 8058 after normal release from goodstherein, such as purge associated with meats. A connection tube 8052 iscoupled to pump 8054 in such a manner so as to allow pumping of anyaccumulated purge or liquids 8018 via tube 8056. Tube 8056 is connectedto a spray nozzle arrangement 8064 mounted on the internal wall ofvessel 8058 at an upper location of vessel 8058. In this way purge 8018can be sprayed in a spray 8010 onto the upper surface of goods 8012 andthereby be returned to its source within vessel 8058. Purge 8018 mayreticulate downward and again accumulate in 8016 and so be recycled bypumping again through tube 8052. Purge 8018 may also be treated with anysuitable agent such as suitable bactericide, prior to spraying at 8064and thereby reducing bacteria content and improving safety of the groundmeat product for human consumption. With the apparatus herein disclosed,it can be seen that goods 8012 can be transferred via conduit 8002through measuring device 8004 and valve 8006 and into vessel 8058 in amanner that substantially excludes ambient air. Measuring device 8004can provide a means to measure the quantity of fat and/or water and/orprotein in goods transferred there through. In this way, the value ofgoods in vessel 8058, based on current market pricing, can beimmediately and automatically calculated as it is transferred therein. Avalve 8020 is mounted directly beneath conduit 8016, which in turnconnects to positive displacement pump 8022. Valve 8020 is arranged toprovide a means to substantially isolate vessel 8058 in a gas and liquidtight manner. Positive displacement pump 8022 is arranged to pump goods,as may be required, through fine grinder 8024 and subsequently extrudefine ground goods, such as ground beef, directly into packaging trays,such as 8028, that is positioned adjacent thereto. Alternatively, anyother processing arrangements such as pattie manufacturing equipment,can be connected directly to the downstream and exit end of pump 8022,and in such a manner so as to allow any selected processing methods ofgoods. The exit end of pump 8022 may be enclosed in an enclosure that isfilled with an oxygen free and suitable gas, selected for it's foodproduct quality and storage life enhancing properties.

Referring now to FIG. 276, a cross section of a portion of the meatpackaging system is illustrated. A pair of horizontal conveyors 8072carry a tray 8068 loaded with meat 8066. A space is defined between thehorizontal conveyers 8072, such that a ink jet printer 8074 can residebetween the conveyors 8072. The ink jet printer 8074 can print a barcodewith information such as weight and date of packaging the meat product8066.

Referring now to FIG. 287, a schematic illustration of a system fortransacting commerce over a communication network according to thepresent invention is illustrated. The meat processing equipment isresident within a meat processing plant 9000. The meat processingequipment can be the processing and storage equipment illustrated inFIG. 275 or any of the equipment, which can reside within a meatprocessing plant 9000, as described in this disclosure. The meatprocessing plant is connected to a communication system, such as theinternet 9006, via a seller computer 9004. A person of ordinary skill inthe art will appreciate that seller computer 9004 can include aplurality of computers connected within a LAN environment. Furthermore,the seller computer 9004 can be connected to one or a plurality ofoperator terminals having a monitor, user interface and input devices.Referring now to FIG. 288, the seller computer includes a centralprocessing unit 9012 (hereinafter “CPU”), network interface 9100,display 9104 and mass memory 9106. Residing within the mass memory ofthe seller computer 9004 are instructions for providing a graphical userinterface (hereinafter “GUI”), a database 9110, and an operating system9112. The database may contain historical sales data, traffic, weather,or road information to enable the determination of an estimated deliverytime to a buyer's designated destination. Such historical information,when used in this manner can provide a means of more accurate predictionof actual sales of fresh meat products, for example ground beef and beefpatties are purchased and consumed by consumers at barbecues, morefrequently and in larger quantities during the hot summer week end andholiday periods, when compared to colder periods when barbecues are aless appropriate and popular recreational event. Referring again to FIG.287, the seller computer is connected to the internet 9006, which inturn is connected to one or a plurality of buyer computers, 9008, 9010,9012. The buyer computers are used to place an order specifying one ormore specifications, such as quantity of meat, type of meat, fatcontent, lean meat content, weight, size, or any other of a plurality ofspecifications which is useful for quantifying meat products. The sellercomputer 9004 receives purchase orders via the internet 9006, with acentral processing unit receiving the order and processing the order todetermine which variables or parameters to manipulate in the meatprocessing plant 9000 to fulfill the buyer specifications. The sellercomputer 9004 may vary the rate of production of a processing train oradjust the content of fat in proportion to lean tissue by controllingvalves, pumps or direct a slicing or cutting machining to cut apredetermined amount of product in differing sizes or shapes. The sellercomputer 9004 can also contain instructions to extract weather orhighway and road information from other servers 9014 and 9016 connectedto the internet 9006 to compute an estimated delivery time at thebuyer's designated destination. The seller computer 9004 includesprogrammable instructions to direct certain events to occur when theestimated delivery time to the buyer's specified destination are inexcess of the allowable amount of time that meat can remain in afinished package without undergoing significant oxidation such that itwould become unsalable. Meat packaged in a controlled atmosphereenvironment of carbon dioxide according to the present invention canendure for about 6-9 days after exposure to ambient atmospheric gas at36 degrees F., without undergoing significant discoloration orrancidity/oxidation. If however, the estimated time of delivery willexceed this recommended amount, the seller computer 9004 can direct thatthe buyer's order be packaged in a gas barrier master containercontaining a substantially oxygen free gas. Packaging in a mastercontainer extends the shelf-life of finished packages for about anadditional 6 weeks. However, if the estimated amount of time necessaryto deliver the buyer's order to the designated delivery destination isless than the amount of time before sufficient discoloration orrancidity/oxidation sets in, then the buyer's order does not need to bepackaged in a low oxygen gas barrier master container, thus reducing theaverage cost per pound of meat product because average packaging costscan be reduced. Once packaged the meat is delivered to the buyer throughconventional channels, such as by refrigerated truck 9002, rail, or shipto the buyer's designated destination. The memory of the seller computer9004 contains programmable instructions for carrying out the presentinvention. One method carried out by seller the computer 9006 isillustrated in FIG. 290. The method includes an event for receivingbuyer specifications 9300. The seller computer will then execute a setof programmable instructions designed to carry out the buyer's order inevent 9302. The seller computer may for instance issue instructions thatresult in accelerating a pump and conveyor to increase the rate ofproduction, or open a valve to mix any number differing meat streams ofdiffering fat content to arrive at the buyer's specification for fatcontent. Other instructions can direct a cutting machine or slicingequipment, sealing station, weigh station, counter, collating or orderconsolidation/assembly direct from the packaging line or from packagesheld in storage, followed by palletizing to meet the buyer's order.Further, the seller computer will determine whether it will be necessaryto package the finished trays in a barrier master container, which caninvolve calculating an estimated time of arrival to the buyer'sdesignated destination 9304, or estimated time of arrival at the pointof sale to a consumer, after delivery to a distribution center. Theseller computer can receive any desirable parameter and necessaryinformation to carry out the instructions either from a residentdatabase of previous buyer data or the seller computer may gather theinformation from the internet from other computers 9014 and 9016. Theseller computer may use weather information 9312 or transportationinformation such as road or highway conditions 9310. The seller computercontains instructions to package a buyer's meat order in a mastercontainer 9306, when it is determined that an unacceptable level ofdeterioration will occur to the packaged meat if it is not packaged in amaster container. The seller computer will then instruct the packagingtrain to package, palletize and ship the product to the buyer 9308. Theseller computer can also have access to the buyer historical data to usein computing the quantity or type of meat which is purchased by buyers.

In another alternate embodiment of the invention, the buyer can beinvoiced from the measuring devices located upstream of the vessels. Forexample, the measuring devices located after the grinding heads can beused to invoice the buyer, while the meat is still held in storage inthe vessels. In this manner the product can be specifically tailored toan individual buyer's specifications.

Furthermore, the present invention can also provide for a method ofcompensating for surge in the blending process. For example, surge canbe eliminated by excluding any gas in the meat streams, but ground meatis elastic and can continue flowing at a rate exceeding the pumpingvelocity after the pump has been slowed or stopped. Alternatively, whenthe pumping velocity is accelerated, the actual velocity may lagmomentarily. The above has an effect on blending accuracy, particularly,when the on-line fat, water & protein measuring device is locatedupstream from the continuous blender. As the meat streams (two or more)emerge from their respective conduits directly into the blending conduitthe fat, water and protein (fat and lean) content of each streamdetermines the velocity of the respective streams. The fat and leancontent is measured upstream therefore there is a set distance(measured) between the point of measuring and the point of transfer fromthe conduit to the blender. The pumping speed therefore must be adjustedto compensate for this surge.

Referring now to FIG. 289, a buyer computer includes a network interface9200 for connecting to a communication system, such as the internet, aprocessing unit 9202, a display 9204, a mass memory 9206 includinginstructions for providing a GUI 9208 and an operating system 9210.Buyer computers may be located at supermarkets, supermarket headquarters, or regional centers where all sales data and information iscollected directly from the checkout bar-code reading apparatus locatedat each supermarket. A person of ordinary skill in the art will readilyappreciate that one or more computers can be used by a buyer at a remotelocation to enter purchase orders via the internet. Buyer computers canalso include hand held remote controlling devices. The informationgathered at the point of retail by buyer computers can be gathered andsent to a remote or local regional buying center having another buyercomputer. The regional buying center can communicate with the sellerserver to place an order via the internet. Furthermore, the sellerserver computer can have access to the historical data gathered by buyercomputers as well.

Referring now to FIG. 277, an actual embodiment of a pre-form web withflaps is illustrated. The pre-form web 8100 can be shaped into afinished tray. The web can be constructed of any suitable material suchas PVC, PP or other suitable materials herein disclosed in thisspecification. The method used to form the web can be thermoforming orany other suitable methods. The web 8100 is constructed of a rectangularbase 8102. The base is surrounded by four upwardly extending walls 8104,8106, 8108 and 8110. The walls may be outwardly reclined to facilitatethe removal of the web from a mold or the nesting together in a stack ofsimilar tray pre-forms (not shown). The walls are connected to the base8102 at a lower portion thereof and adjoining walls are connected toeach other thusly forming corner sections. In this embodiment, thecorner sections are made from the ends of the walls being creasedinwardly 8114 where the ends attach to an adjacent wall. Thus, two endsof two walls form an inwardly extending corrugation 8112 to give the webadditional strength when finished into a tray. Two walls 8102 and 8108of the four walls on opposing sides are formed with an upwardlyextending region 8116 in the center, and an angled shaped bottom edge8118 to give the finished trays the ability to be stacked atop oneanother without allowing the sealing web of a lower tray to touch thebase of the adjacent stacked upper tray. While an angled bottom has beenshown, the shape may take an arcuate form. Furthermore, the base isconfigured to have similar angled surfaces or arcuate shape thatcorresponds to the shape of the lower portion of the side walls 8102 and8108. The upper edges of the walls 8104, 8106, 8108, and 8110 areattached to flaps 8120, 8122, 8124 and 8126, respectively. Referring nowto FIG. 278, the flaps are joined to the upper edge of the walls at ahinge 8128 to allow the flaps to rotate inwardly. The finished tray 8130will thusly include an outer 8132 and an inner 8134 reinforcing wallmade from the flaps. The flaps include a tab 8136 connected to one edgeof the flap which can be folded inwardly as shown in FIG. 278 to pressfit into a groove 8138 formed at the lower perimeter of the base 8102.The member formed by the folded tab 8136 thus forms a securing devicewhich is press fitted into the corresponding base groove 8138 withoutthe need for bonding the flaps to the finished tray with adhesivesthereto.

Referring now to FIG. 279, a mold 8200 for forming pre-rigor mortis meatis illustrated. Pre-rigor mortis meat is moldable to form any of avariety of desired shapes by placing quantities of harvested pre-rigormeat into any one of a plurality of mold forms. In one actual embodimentshown in FIG. 279, a mold 8200 is shaped in an elongated form. The mold8200 can be constructed of suitable materials, some of which can beadvantageously permeable to ozone or any other suitable gas orsubstance. The mold 8200 has four walls 8202, 8204, 8206, and 8208. Thebottom wall 8206 of the mold 8200 can be configured to be angled orarcuate such as the base shown in FIG. 277. However, any mold can beprovided with a bottom wall suitably configured to the shape of any ofthe trays herein disclosed. This is provided in a mold so as to enableslicing of the meat into portions of similar size and weight, which canconform to the finished tray to utilize the space within the tray in themost efficient manner. In this way substantially identical slices ofmeat can be produced with virtually no trimming requirement. Whenevertrimming is required, a loss is incurred since the portions trimmed offcan only be used in a product, such as grinds, of lower value than thesliced meat. Identical slices can be sold in packages of “same weigh andsame price”, which is a preferred supermarket strategy as opposed torandomly priced packages that have individual package price determinedby random weight due to inconsistent size and weight of each slice offresh meat contained in a single package. Referring again to FIG. 279,two walls 8204 and 8208 of the four walls form the vertical walls of themold 8200. The vertical walls 8204 and 8208 can be inclined or reclinedto match the configuration of any packaging tray walls. The mold 8200includes a top wall 8202 connecting the two vertical walls 8204 and 8208at a upper portion thereof. The mold 8200 also includes a bottom wall8206 connecting the vertical walls 8204 and 8208 at a lower portionthereof. Thusly formed, the mold 8200 resembles a hollow tube with across-section shape shown in FIG. 280. Although an irregular shapedpolygon is shown as a profile shape, the shape of the mold can be anysuitable shape to resemble a tray's dimensions. The bottom wall 8206 canbe shaped to substantially conform to the tray base as described above.The mold 8200 includes openings formed on opposite ends of the moldthereof. A lip 8210 is formed within a short distance inward from afirst opening of the mold 8200. A plug 8212 fits within the opening andis constrained to move toward the opening by the lip 8210. A second plug8214 is inserted in the mold 8200 from the opposite opening. The secondplug 8214 can be pressed to form the meat to a shape substantiallyresembling the mold 8200. A chip 8216 or proximity switch can beembedded within the plugs to determine the distance from the first plugto the second plug. In this manner, the correct size of the meatportions can be determined. Once the pressing operation is completed,the shaped meat 8218 can be sliced automatically or manually to suit thesize of the finished trays. In this manner, two dimensions are keptconstant which will consistently provide meat portions of constant sizeand weight that can fit within the trays, while advantageously onlyvarying one dimension, which will most preferably be the length of themolded portion. The shaped meat can contain an area of fat 2819.

In another alternate, the mold is provided with a port for injectingdesirable concentrations of gases or for evacuating undesirableconstituents, which can include gases or liquids.

Referring now to FIG. 282, an alternate embodiment of a pre-form webwith flaps is illustrated. The web 8300 includes a base 8302 with fourvertical walls 8304, 8306, 8308, and 8310 connected to the base 8302 atlower edges of the walls thereof. The pre-form web 8300 is preferablyconstructed by injection molding or other suitable methods, such asthermoforming. The walls may be inclined to facilitate the removal ofthe web pre-form from a mold. The base is connected to the walls atlower portions thereof, and the walls are connected to each other atadjacent ends, thusly forming corners 8312, 8314, 8316 and 8318 wherethe ends of walls connected to each other and to the base 8302 meet.Opposing two walls 8310 and 8314 of the four walls are formed withangled edges at a lower central portion thereof to form an recess sothat upon stacking of finished trays, the goods are preferably not incontact with a lower stacked tray. The base 8302 is likewise configuredwith angled surfaces to correlate to the shape of the walls 8310 and8314 so that the base 8302 is aptly suited to minimize contact with thegoods of a lower stacked tray. The upper edges of the walls includeflaps 8320, 8322, 8324 and 8326 suitably constructed so as to inwardlyrotate about a hinge around the perimeter of the opening. Referring toFIG. 283, the flaps are constructed with a number of surfaces 8328 and8330 at desirable oblique or perpendicular angles to impart strength tothe flaps and the finished tray in the form of a structural member. Aswith other trays disclosed herein, the tray of this embodiment isintended to be stackable atop one another. Referring now to FIG. 284, aportion of a finished tray with goods 8332 placed therein and foldedflap 8334 is illustrated.

Referring now to FIG. 285, another alternate embodiment of a pre-formweb for finishing into a tray is illustrated. The web in this embodimentcan be thermoformed of suitable materials disclosed herein or by othersuitable methods known in the arts. The web 8400 includes a rectangularbase 8402 with four walls 8404, 8406, 8408 and 8410 attached at therespective four sides around the perimeter of the base 8402. The wallscontain ribs 8422 to add structural rigidity and strength to a finishedweb. When the flaps are folded, the flaps can be bonded to the ribs,which project outward, thusly allowing bonding of the ribs to the flaps.In this manner, the flap faces 8424 can be pre-printed with a barcodecontaining relevant information or other product description. The wallsare connected to each other at adjacent ends thereof, respectively. Thefour adjacent walls are joined to each other by corrugated sections8412, 8414, 8416 and 8418 joining a first end of a first wall to asecond end of a second wall and so on. When the web 8400 is finishedinto a tray, the corrugated sections will appear as shown in FIG. 286.The corrugated sections are intended to impart rigidity and strength tothe finished tray 8420. For example, under certain thermoforming orinjection molding conditions, the lower corners where the base and wallsare connected, the web material may be stretched or “thinned” out, thuscreating a weak spot and a potential source for leaks. By forming a webwith corrugated corners the weak sections of the finished tray arestrengthened accordingly.

In another alternate embodiment illustrated in FIG. 294, a tray isconstructed with flaps and having contoured ends to substantially lieadjacent to a corner where the base and walls are joined together, whenthe flaps are thusly folded. The flap ends reinforce the corners of thefinished tray by overlapping and/or wrapping around the corner sectionson the bottom and sides thereof. One or two flap ends may be bonded to acorner to reinforce the corners. In one actual embodiment, a tray 9700includes four flap, flaps 9702 and 9704 include contoured end portions9706 and 9708, respectively, rounded to conform to a rounded corner 9710of the web base and walls. A first flap 9702 is folded and bonded to thetray 9700 such that the rounded end portion 9706 of the flap 9702overlaps the corner area 9710. A second flap 9704 has an end portion9708 can be folded on top of the first rounded flap end portion 9706 todoubly strengthen the corner section 9710 of tray 9700, as illustratedin FIG. 295.

A method according to the present invention includes grinding bonelessbeef directly into an enclosed chamber that has been filled with asuitable gas such as CO2 and which substantially excludes oxygen fromcontacting with said ground beef. Adjusting temperature of said groundbeef to a suitable temperature. Processing and mixing ground beef(meat), in a vessel or series of vessels substantially excluding oxygen,so as to blend and adjust the relative quantities of fat and muscle inthe finished product to a desired ratio can take place, whilemaintaining the ground beef at a suitable temperature. The ground beefcan then be extruded in a stream of grinds by pumping through anenclosed conduit with an exit end and a selected cross sectional areaand profile that is substantially similar to typical beef pattie, at avelocity that is adjustable while maintaining pumping at a substantiallyconstant rate. The stream of ground beef can be pressurized in a conduitat a selected pressure and compressing any voids such that CO₂ gascontained therein dissolves into the stream of ground beef, whilecontinuing to maintain ground beef at a suitable temperature. Thevelocity of the stream of grinds can be adjusted so as to intermittentlyslow or stop it's flow as it emerges from the exit end of the enclosingconduit and allow slicing with knife means to provide single beefpatties in stacks of a chosen quantity. Intermittent slowing or stoppingof flow may exceed 500 cycles per minute. The processed meat isinterfaced with a packaging system which packages the fresh meat pattieswithout exposure to air while continuing to maintain at a suitabletemperature.

Referring now to FIG. 291, a schematic illustration of a plant layout isshown. The plant layout includes a processing stream or train, forprocessing meat. In one section of the plant, sources of meat 9454,9456, and 9458 are transferred to meat grinders 9402, 9404, and 9406. Asuitable supplier for meat grinders is the Weiler Company, Inc. ofWhitewater, Wis. The meat grinders are connected to downstreampre-blending and transfer equipment 9408, 9410 and 9412, which mayinclude screw and/or belt conveyers and pumps as the transfer equipment.The pre-blending and transfer equipment may be supplied by the WeilerCo. and the continuous blending equipment supplied by Case ReadySolutions, LLC of Mercer Island, Wash. The pre-blending equipment isconnected to on-line measuring devices 9414, 9416, and 9418,respectively, for measuring the amount of fat to lean meat ratio. Themeasuring devices can be supplied by Epsilon Industrial of Austin Tex.or Holmes/Newman of Fallbrook, Calif. The transfer equipment includespositive displacement pumps supplied by the Weiler Company. Downstreamfrom the measuring devices, the meat is transferred to continuousblending equipment, 9420 where the meat is blended in a controlled ormodified atmosphere, which substantially excludes oxygen. At this pointone or a plurality of meat streams can be fed into the blendingequipment to provide for meat grinds of a desired constituency of fatand lean meat, therefore the continuous blending equipment includes aproduct entry port for one or a plurality of meat streams. Thecontinuous blending equipment is supplied by Case Ready Solutions, LLCand Wenger of Sabetha, Kans. While a continuous blending process ispreferred for consistency and efficiency, the ground meat can be fed inbatches with holding vessels interspersed throughout the process, themeat can then transferred to one or more vessels 9432, 9434, 9436 and9440 for temporary storage. One vessel 9438 may serve for rejects or offspec product. Temperature control by injection of carbon dioxide can beadjusted to between about 29 to about 38° F., the pressure is held toless than about 40 psi, in the continuous blending equipment and vesselsbut the pressure is kept to less than about 10 psi elsewhere throughoutthe equipment. Continuous blending equipment 9420 can be horizontallydisposed and elevated to provide for a gravity feeding arrangementalternately and to either of vessels 9432, 9434, 9436 and 9440. Aquantity of any specified blend of fat and lean grinds, sufficient tofill a vessel is produced followed by a quantity of another specifiedblend of fat and lean grinds, sufficient to fill a second vessel.Vessels can be supplied by the Weiler and Company. Blended grinds aretransferred from each vessel by suitable conveying and transferequipment such as positive displacement pumps to meat portioners 9422,9424, 9426, and 9428, where the meat is extruded and sliced into desiredportions by size or weight. Feeding may be continuous or in batches asrequired. The packaging section of the plant includes a conveyor system9446, 9448, 9450, and 9452 for moving unfinished webs through stations,where webs are finished into trays and loaded with goods, such asportioned meats. After the goods have been loaded into trays, the traysare sealed by a second web, such as may be provided with the Hayssenmodel RT1800, 9442 and 9444, with the modifications described hereinabove. Further packaging may include loading into master containers,depending on the circumstances and palletizing, according to a buyer'sspecifications. The processing of the ground meat is conducted in acontrolled or modified atmosphere having little to no exposure tooxygen. Suitable gases are described in the specification. The equipmentis preferably automated and controlled by a computer 9460, such asequipment supplied by the Wenger Co. The computer can be connected toone or more buyer computers via a communication system, such as theinternet, for automatically receiving and filling orders from buyers,such as supermarkets.

Referring now to FIG. 292, a schematic representation of a packagingarea of a meat processing plant is illustrated. The packaging area caninclude one or a plurality of processing trains. In one embodiment, thepackaging area 292 includes three sources of webs 9502, 9504, and 9506for processing the unfinished webs. A web treatment train includesmagazines 9508, 9510, and 9512 containing the webs, gas treatment andsterilizing equipment, and bonding equipment to produce the finishedtrays from the unfinished pre-form webs. Under some circumstances,bonding equipment may not be necessary for non-bonded trays which can beproduced by using pre-form webs not requiring bonding. There can be oneor a plurality of unfinished web streams, which can produce finishedwebs of differing sizes as required. The equipment in this area can besupplied by PMI Cartoning Inc. of Elk Grove Village, Ill., withadhesives supplied by National Starch and Chemical (a division of theICI Group) of Bridgewater, N.J. The tray treatment section is linked toconveyor and transfer equipment which moves individual finished traysalong a conveyor, while meat grinding, portioning and loading apparatus,9514, 9516 and 9518 processes the meat stored in vessels 9520, 9522, and9524 which is then loaded as goods into the finished trays. The trayscan then be weighed and labeled with a bar code containing relevantinformation. The weighing and labeling equipment can be supplied by theHerbert Industrial of Haverhill, Suffolk, UK. The trays with goods arethen sealed with a second web. The finished packages continue to travelon conveyors where the packages can be directed to a stacking apparatus9528, such as drop loaders, supplied by PMI Cartoning, Inc. At thestacking apparatus, further equipment can produce thermoformed cartons.Thermoforming equipment 9530 can be supplied by Cott Technologies Inc.of La Puente, Calif. The finished packages can then be loaded andstacked into the newly thermoformed cartons. The auto carton equipmentcan be supplied by PMI Cartoning, Inc. The cartons are then palletizedin palletizing equipment 9534 and made ready for shipment to a buyer'sdesignated delivery destination. For the majority of the meatprocessing, the meat is excluded from substantial contact with oxygen tominimize oxidation. Therefore desirable concentrations of gases arecontinually being used to pad processing equipment. This equipment canbe supplied by the BOC Gases company. Other equipment is developed toremove undesirable gases by using vacuum equipment. Vacuum equipment canbe supplied by the Kinney Co of New York or the Reitschle vacuum pumpmanufacturing company of Germany. Conveyor and or transfer equipment canbe supplied by PMI Cartoning, Inc. While three differing webs for traysmay be provided at the loading station, each master container isprovided with a manner of identifying an allocated destination. Themaster containers are palletized to ship where they are needed by thebuyer or alternatively may be placed in storage. The computer controlleris provided with a set of instructions to manage, in cooperation withthe input provided for by an operator interface, the processing andpackaging of the meat goods.

Referring now to FIG. 293, a schematic illustration of web treatment andwelding equipment is shown. In one embodiment, the equipment includestray loading magazines 9602 and gas exchange magazines and chambers9604. A nitrogen gas generator 9612 is provided to pad the equipment,providing an inert environment to substantially exclude oxygen. Thenitrogen generating equipment can be supplied by the BOC company. Thetrays travel on a delivery conveyor to an adhesive applicator andbonding equipment 9606, where the trays are formed from webs and thenbonded to produce the finished trays. The adhesive applicator andbonding equipment can be supplied by National Search and Chemical. Undersome circumstances, the trays can be formed without bonding, such asfrom the pre-form web with tabs on the foldable flaps. The finished websare then delivered where needed on the meat processing train where needby a delivery conveyor 9608. The section of the plant for finishingtrays is controlled by controller computer 9610. The computer 9610 canbe integrated with other sections of the plant to provide for just intime delivery of finished webs.

The present invention provides an efficient method of processing freshred meat products at the point of animal slaughter for subsequent caseready packaging and delivery to the consumer via a typical supermarketor retail sale outlet. The consumer may be located thousands of milesaway from the point of slaughter which often results in distribution anddelivery that can require a period of time exceeding 20 days.

Perishable food products produced, in part or otherwise, in the mannerdescribed herein may be placed in any suitable tray with or without anysuitable substance and over wrapped with any suitable web of materialsuch as pPVC (or PE) and then placed in a master container that may bemanufactured from a substantially gas barrier material or partial gasbarrier material to provide finished packages. Following this, finishedpackages may be stored in any suitable storage room maintained at anysuitable temperature until required for sale, at which time finished maybe removed, labeled and displayed for sale in a retail outlet such as asupermarket.

Referring now to FIG. 296, a schematic illustration of an embodiment ofa plant layout according to the present invention comprising anautomated system of pre-treating packaging components and perishablegoods such as ground meats is shown. The arrangement as shown includesfour production lines for the portioning, loading, over-wrapping andassembly of barrier master container packages. Four empty tray conveyorsare shown as 9800. Trays are transferred along conveyors 9800 totransverse conveyors 9802, 9804, 9806, and 9808. A continuous mixer 9810is arranged to deposit selected ground beef into any one of four silos9812, 9814, 9816, and 9818. Each of silos 9812, 9814, 9816, and 9818 isarranged with a positive displacement pump attached thereto such thatground meat can be pumped via conduits (not shown) from silo 9812 tofine grinder 9820, from silo 9814 to fine grinder 9822, from silo 9816to fine grinder 9824, and from silo 9818 to fine grinder 9816. A dumpsilo 9828 is provided such that any quantities of material that aredetermined to be unsuitable for packaging can be transferred therein.Fine grinders 9820, 9822, 9824, and 9826 are attached respectively toportioning equipment 9830, 9832, 9834, and 9836. Empty trays transferredalong conveyors 9800 are loaded with ground meat portions from portioner9830 at conveyor 9802, from portioner 9832 at conveyor 9804, fromportioner 9834 at conveyor 9806, and from portioner 9826 at conveyor9808. Conveyors 9838 transfer loaded trays from each loading conveyor9802, 9804, 9806, and 9808 to weighing scales 9840, 9842, 9844 and 9846,respectively. Labels with weight and product information as required,are applied to the bottom of loaded trays, by bottom label applicators9848, 9850, 9852, and 9854, respectively. Loaded trays are then overwrapped by flow packers 9856, 9858, 9858, and 9860, respectively.Automatic stackers 9862, 9864, 9866, and 9868 stack selected groups ofloaded over wrapped trays which are then transferred and automaticallyloaded by automatic loaders 9876, 9878, 9880, and 9882, into gas barriercontainers formed in line on horizontal thermoforming machine 9870.Conveyors transfer trays from the flow packers to the automaticstackers. An automatic carton erection apparatus 9872 is arranged toenclose each barrier master container in a carton, which is thentransferred to an exit conveyor 9874. A central control panel 9884 islocated conveniently to allow control of the complete system. Continuousmixer 9810 and silos 9812, 9814, 9816, and 9818 may be located in anadjacent room separated by an insulated wall such that the contents ofthe silos can be maintained at a selected temperature which maybe 34degrees F.

Referring now to FIG. 297, a schematic, cross sectional illustration ofa section of the plant layout according to the present invention isshown in FIG. 299. The plant is located on a factory floor, 5000, and ata convenient elevation from the floor, in an enclosed, suitablyventilated room that is temperature controlled at about 38 degrees F. Agenerally horizontally disposed conduit is defined by an outer,substantially gas tight, enclosure 3001. Packaging components such astray performs 3021 and web materials 3011, and ground meat 3027 aretransferred into the conduit 3001 in such a manner so as tosubstantially exclude the entry of atmospheric oxygen and a gas 3032 isprovided in any space inside conduit 3001 that is not occupied byequipment or goods. Gas 3032 is selected and may comprise any suitablegas such as carbon dioxide or nitrogen and is maintained at a pressureabove ambient atmospheric pressure. A conveyor 3024 is convenientlymounted within conduit 3001 and arranged to carry trays 3020 therethrough. Tray pre-forms 3021 are stacked into profiled and verticallydisposed magazines 3023 and 3099. Magazines 3023 and 3099 are arrangedto have an outer wall that closely, but not touchingly, follows theouter profile of the stacks of pre-form trays 3021, contained therein.De-nesting mechanisms (not shown) are arranged to remove a singleperform from the bottom of a stack such as contained in magazine 3023and position it onto conveyor 3024. In this way, gas contained withinconduit 3001 can then fill the cavity in tray perform and therebysubstantially preventing any atmospheric oxygen or other undesirablegases from entering into the tray cavity. Tray pre-forms 3021 are thencarried in the direction shown by arrow 3031 to a position below thefolding and bonding arrangement not shown but housed within enclosure3017. During the folding and bonding of pre-form 3021 to form tray 3020gas 3032 fills all cavities or interstitial voids contained in the trayand in this way it is ensured that only a selected and suitable gas iscontained therein. Finished empty trays 3020 are then placed by 3017onto conveyor 3024 and carried forward to be loaded with portions ofground meat 3027. A stream of selected ground meat is transferredthrough conduit 3100 at a convenient velocity and into fine grinder 3028and in such a manner so as to extrude a continuous and suitably crosssectional profiled stream of ground meat 3101 onto conveyor 3024.Extruded stream 3101 is extruded into conduit 3001 and onto conveyor3024, mounted therein, at a suitable velocity so that guillotine 3026can cut portions of substantially similarly sized ground meat sectionsthere from. Portions of ground meat 3027 are then transferred into trays3020 which are there together transferred through conduit 3001 onconveyor 3024. Conveyor 3024 can be arranged with upwardly disposed“cleats” 3080 or a series of suitable enclosures to ensure that whenground meat portions 3027 are loaded into trays 3020 the tray ispositioned precisely beneath the respective ground meat portion,allowing accurate loading into tray 3020 to produce a loaded tray withgoods 3030. Loaded trays with goods 3030 are then transferred throughconduit 3001 toward over wrapping equipment arranged to over wrap trays3030. A roll of suitable over wrapping web material 3010 is convenientlymounted above conduit 3001 and is unwound by transferring a single webof material 3011 through a slot like conduit 3012. Gas contained inconduit 3001 at an elevate pressure can pass over the surfaces of web3011 while it passes through slot like conduit 3012 and in this wayensure that substantially no atmospheric oxygen is allowed to enterconduit 3012 or conduit 3001. Over wrapped and hermetically sealed trays3102 are transferred along conduit 3001 toward robot stackingarrangement 3014. Robot 3014 is enclosed in a housing that forms a partof conduit 3001 and is programmed to stack trays 3102 into groups 3015that are then loaded into gas barrier containers 3013. Gas barriercontainers 3013 can be formed in line and flushed with a suitable gasprior to loading of stacks 3015 therein. Horizontal thermoformingmachine 3016 is conveniently located below robot 3014 and is arranged sothat the thermoformed barrier containers 3013 are enclosed within anextension of conduit 3001 and thereby ensuring that gas 3032 is incontact therewith and filling cavities in barrier containers 3013.

Referring now to FIG. 298 the tray de-nesting apparatus portion of FIG.297, before the pre-form flaps have been bonded to the tray walls, isshown in a cross sectional view. Vertically disposed walls 3023 arearranged to closely conform to the outer edge perimeter of the stackedpre-forms 3021. A narrow gap is thereby maintained between the stack3021 and magazine walls 3023 allowing the tray pre-forms to slidethrough the magazine without restriction, as the lowest tray performsare progressively removed and placed onto conveyor 3024. Gas 3032, fromconduit 3001, is exhausted through the narrow gap at 3040 and additionalselected gas such as 3032 can be injected through conduits 3022 at asuitable pressure so as to substantially fill spaces between the stackedpre-forms as they are gradually transferred through magazine 3023.

Referring now to FIG. 299, a schematic illustration of an embodiment ofan specially arranged thermoforming apparatus is shown according to thepresent invention. The apparatus shown in FIG. 299 is intended toprovide an alternative, preferred and economical method of deliveringtrays to conveyor 3024 as shown in FIG. 297. A wheel 3066 is mountedonto a shaft 3070. Wheel 3066 is arranged to have 8 flat sides, ontowhich tooling 3067 can be mounted. Wheel 3066 is attached directly to asprocket (not shown), which engages with a pair of continuous gripperchains 3073. Other sprockets including idler sprockets 3075 and drivesprockets 3074 are mounted to maintain gripper chains 3073 follow afixed and generally horizontally disposed track. A roll ofinterchangeable and thermo-formable material 3064 is located betweenchains 3073 and is unwound in a continuous web of material 3063. As web3063 is unwound from roll 3064 it is held by gripper chains 3073 at eachside edge and withdrawn, at a suitable rate, from roll 3064 by theforward motion of chains 3073. Sprockets 3074 are attached to a suitabledrive motor with controller that progressively carries web 3063 betweenheat banks 3062. Heat banks 3062 are mounted in close proximity aboveand below web 3063 and as gripper chain 3073 carries web 3063 therebetween is heated. The temperature of heat banks 3062 is controlled andmaintained within a selected range so as to ensure that the temperatureof web 3063 is at a thermo-formable temperature as it passes frombetween heat banks 3062 and onto a face of wheel 3066. Rollers 3060 and3061 are arranged to contact the upper and lower surfaces of web 3063and apply a calendering pressure thereto. Rollers 3062 and 3061 aremaintained at a temperature as required. Eight sets of tools 3067 aremounted to wheel 3066. Each tool 3067 comprises a four-sided tray cavityforming depression with a flat forming depression adjacent to each side,such that a pre-form with four flaps can be formed therein. Clampingfixtures with plugs or matching molds 3065 are arranged to convenientlybe incorporated as required while the pre-form being formed in matchingtools 3067. Forming tool 3067 can be arranged such that the flap formingsections of the tool can be hinged so as to fold the flaps after cuttingfrom web 3063, and become bonded to walls of the tray cavity prior toejection. In this way, a pre-form tray can be thermoformed, cut from theweb 3063, folded and bonded, and ejected by tools on wheel 3066. Afinished tray 3020 is then ejected and allowed to fall in the directionas shown by arrow 3068, onto conveyor 3024. Enclosure 3001 is arrangedto completely enclose the wheel assembly 3066, clamping arrangements3065 and conveyor 3024, and in such a manner to ensure that all cavitiesbetween walls and flaps of tray 3020 are filled with selected gas 3032.Web 3063 may comprise a solid extruded sheet of plastics material,extruded from any suitable polymer, with an additive contained thereinthat will generate a suitable gas such as carbon dioxide when heated toa thermo-formable temperature. Web material 3063 may comprise apolypropylene polymer with any suitable additive such as a filleradditive containing calcium bicarbonate that will release carbon dioxidegas when heated, within the extruded polymer sheet, to a thermo-formabletemperature. In this way, an expanded polypropylene sheet (EPP) ofmaterial can be formed immediately prior to use, and ensuring thatcarbon dioxide gas fills the interstitial spaces within the web materialfrom which trays 3020 are formed.

Referring now to FIG. 300, a section of web 3063 is shown with athickness 3073, which may be for example 0.010 inches, prior to heating.A section of web material 3071 is shown with thickness 3072 which may befor example 0.030 inches thick. As shown, web 3063 can be increased inthickness from 0.010 inches to 0.030 inches, by heating to athermo-formable temperature.

Modifications may be made to the inventions as would be apparent topersons skilled in the packaging arts. These and other modifications maybe made without departing from the ambit of the invention, the nature ofwhich is to be determined from the foregoing description.

Any suitable substance, gas, blend of gases, solution or agent may besubstituted, included as an alternative or included with any suitablegas or blend of gases that has been specified for any use or applicationin this disclosure.

While the preferred embodiment of the invention has been illustrated anddescribed, it will be appreciated that various changes can be madetherein without departing from the spirit and scope of the invention.

1-215. (canceled)
 216. A method for processing meat, comprising: cuttingmeat containing deoxymyoglobin in an atmosphere substantially deficientof oxygen to provide cut meat having freshly cut meat surfaces; andinhibiting contact between the freshly cut meat surfaces with oxygenfrom just after cutting the meat through packaging the meat in a packageto extend the shelf life of the packaged meat. 217-265. (canceled) 266.The method of claim 216, further comprising immersing the freshly cutmeat surfaces within an atmosphere substantially deficient of oxygenuntil the cut meat is packaged.
 267. The method of claim 216, whereincutting meat comprises grinding the meat.
 268. The method of claim 216,wherein the atmosphere comprises substantially carbon dioxide gas andnot more than 0.4% carbon monoxide.
 269. The method of claim 216,further comprising pre-conditioning the meat with carbon dioxide gas ata pressure equal to or above atmospheric pressure prior to cutting themeat.
 270. The method of claim 216, further comprising pre-conditioningthe meat with carbon dioxide gas at a pressure above atmosphericpressure prior to cutting the meat so that when the meat is returned toatmospheric pressure, the carbon dioxide will be released at or near thefreshly cut meat surfaces to inhibit contact with oxygen.
 271. Themethod of claim 216, further comprising lowering the temperature of themeat prior to cutting the meat.
 272. The method of claim 216, furthercomprising lowering the temperature of the meat to less than 32° F.prior to cutting the meat.
 273. The method of claim 216, furthercomprising adding solid carbon dioxide with the meat during cutting tocover the freshly cut meat surfaces with carbon dioxide to inhibitcontact between the freshly cut meat surfaces with oxygen.
 274. Themethod of claim 216, further comprising transferring the cut meat in anenclosed, carbon dioxide- or nitrogen-filled conduit to a packagingmachine to minimize the contact of the freshly cut meat surfaces to theoxygen in the ambient atmosphere.
 275. The method of claim 216, whereinthe atmosphere comprises not more than 5% oxygen.
 276. The method ofclaim 216, wherein the atmosphere comprises carbon dioxide, nitrogen,and not more than 5% oxygen.
 277. The method of claim 216, wherein theatmosphere comprises at least one of pentane, propane, butane, methane,a CFC, an HCFC, carbon monoxide, or sulfur dioxide.
 278. The method ofclaim 216, wherein the atmosphere is about 100% carbon dioxide gas. 279.The method of claim 216, wherein cutting comprises grinding the meatwith a grinder and the outlet of the grinder is coupled to a conduitcontaining a packaging machine, wherein packaging of the meat is done inan atmosphere substantially deficient of oxygen.
 280. The method ofclaim 216, wherein cutting comprises grinding the meat with a grinderand the outlet of the grinder is coupled to a vessel containing anatmosphere substantially deficient of oxygen.
 281. The method of claim216, wherein cutting comprises grinding the meat with a grinder and theoutlet of the grinder is coupled to a conduit containing a packagingmachine, wherein the conduit is filled with an atmosphere substantiallydeficient of oxygen.
 282. The method of claim 216, wherein cuttingcomprises grinding the meat with a grinder and the outlet of the grinderis coupled to a conduit containing a packaging machine, wherein theconduit contains a controlled atmosphere substantially deficient ofoxygen, wherein the packaging machine includes a thermoforming machineto form trays in an atmosphere substantially deficient of oxygen. 283.The method of claim 216, wherein cutting comprises grinding the meatwith a grinder and the outlet of the grinder is coupled to a conduitcontaining processing and packaging equipment, wherein the conduitcontains a controlled atmosphere substantially deficient of oxygen,wherein the packaging machine includes a chub packaging machine to formpouches within an atmosphere substantially deficient of oxygen.
 284. Amethod for processing meat, comprising cutting meat to provide cut meathaving freshly cut meat surfaces; and, thereafter, inhibiting contactbetween the freshly cut meat surfaces with oxygen from just aftercutting through processing and then packaging in a package.
 285. Amethod for pre-conditioning meat prior to cutting, comprising:pre-conditioning meat prior to cutting with carbon dioxide gas at apressure above atmospheric pressure to displace ambient atmosphericgases and substantially saturate the liquid phase of the meat withcarbon dioxide; and after cutting the pre-conditioned meat, allowing thesaturated gas to be released from the meat to inhibit contact of the cutsurfaces with oxygen which lasts through packaging the pre-conditionedmeat in a package, wherein the meat can release carbon dioxide into thepackage.